WORKSHOP MANUAL

SISUDIESEL
8366 40634

320
420
620
634

Sisudiesel
320, 420, 620, 634
engines

Workshop Manual

02 02

Sisu Diesel Inc.

FIN37240 Nokia, Finland

Telephone: +358 3 341 7111
Email: [email protected]
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

Contents

CONTENTS
TO THE USER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---1
ENGINE TYPE DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---2
ENGINE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---3
LIFTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---3
LOCATION OF THE ENGINE SERIAL NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---4
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---6
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---6
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---6
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---6
Valves, rocker arms and tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---7
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---7
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---8
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---8
Balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---9
Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---9
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---9
Piston, piston rings and pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---10
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---10
Oil pump (320, 420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---10
Oil pump (620, 634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---11
Coolant pump (320, 420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---11
Coolant pump (320, 420 separate ball bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---11
Coolant pump (620, 634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---12
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---12
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---13
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---14
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---14
Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---14
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---15
Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---15
Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---15
Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---16
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---17
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---18
Inlet and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---19
Electronic Engine Management system (EEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---20
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. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2
F. Fitting plug at camshaft rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---3
G. Fitting pipe for oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---4
H. Fitting cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---4
2. FLYWHEEL HOUSING
A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---1
B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---1
3. CYLINDER HEAD
A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---2
E. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---2
F. Changing valve seat ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---4

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Contents
4. VALVE MECHANISM
A. Reconditioning valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---1
B. Changing camshaft/camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---2
C. Adjusting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---3
5. CRANKSHAFT
A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---1
B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---1
C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---1
D. Changing crankshaft gear rim (420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---2
E. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---2
F. Crankshaft hub piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---3
G. Changing crankshaft pulley/vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---3
H. Checking element of the rubber damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---4
I. Viscose type vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---4
6. CONNECTING RODS AND PISTONS
A. Removing pistons together with connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
D. Changing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---3
E. Checking pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---3
F. Fitting piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---4
G. Fitting piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---4
7. COUNTERBALANCE (420)
A. Removing and disassembling counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7---1
B. Reconditioning counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7---1
C. Fitting counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7---1
8. FLYWHEEL
A. Changing starter ring gear on flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8---1
B. Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8---1
9. TIMING GEAR ASSEMBLY
A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---1
B. Reconditioning idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---1
C. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---2
D. Idler gear with bevelled ball bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---4
E. Power take ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---5
10. LUBRICATION SYSTEM
A. Reconditioning of oil relief valve for lubricatin oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---1
B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---1
C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---2
D. Fitting oil sump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---3
E. Lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---3
F. Piston cooling nozzles (620, 634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---3
G. Lubrication oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---4
11. COOLING SYSTEM
A. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---1
B. Reconditioning coolant pump (320, 420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---1
C. Reconditioning coolant pump (320, 420, 620, 634 separate ball bearings) . . . . . . . . . . . . . . . 11---2
D. Coolant pumps with heavy ---duty bearings (620, 634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---4
E. Quality requirements of coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---4
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
13. FUEL SYSTEM
IN ---LINE FUEL INJECTION PUMP
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---1
A. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---6
B. Bleeding Thermostart system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---6
C. Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---7
D. Checking overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---7
E. Changing fuel feed pump valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---7
F. Checking injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---8
G. Adjusting fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---9

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H. Removing fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---10
I. Fitting fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---10
J. Checking and changing pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---12
K. Adjusting idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---12
L. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---13
M. Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---13
N. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---14
O. Fitting injector in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---15
P. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---15
CAV DISTRIBUTOR PUMP
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---16
A. Dismounting and mounting injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---17
B. Injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---17
C. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---17
D. Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---18
E. Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---18
STANADYNE DISTRIBUTOR PUMP
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---19
A. Removing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---24
B. Fitting injection pump and adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---24
C. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---25
D. Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---25
E. Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---25
F. Adjusting low idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---26
G. Bleeding Thermostart system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---26
H. Wiring diagram of electrical advance (CCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---26
I. Checking injection timing (dynamic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---27
Fuel quality requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---29
14. EQUIPMENT AND FEEDING TABLES
15. ELECTRICAL SYSTEM
A. Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---1
B. Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---4
C. Electric stop device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---7
D. Installation of magnetic pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---9
E. Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---9
16. OPTIONAL EQUIPMENT
A. Compressor (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16---1
B. Compressor (Knorr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16---2
C. Industrial clutch (A.P. Borg & Beck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16---3

0---0

To the User

0---1

TO THE USER
This Workshop Manual is intended to facilitate workshop operations and repair work.
320, 420, 620 and 634---engines 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 +20C, 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 20/34---series Operators Manual.
As Sisu Diesel Inc. is continuously developing the products, all rights are reserved without separate notice to change the adjustments, accessories and service --- and repair procedure.

ENGINE TYPE DESIGNATIONS

420 DSRIEL
Application
A = vehicle engine
G= generating set engine
L = combine harvester engine
M= marine engine
P = pump set engine
E = emission tested engine (certified) for off---road
C = emission tested engine (certified) for on---road
Equipped with intercooler
A = air to air
I = air to water
Rotary fuel injection pump (B, if equipped with Bosch P---type
injection pump)
Turbocharged engine (W, if equipped with by---pass turbo)
Basic type (E, if equipped with electronic engine control)
Number of cylinders (3, 4 or 6)

Safety Instructions

SAFETY INSTRUCTIONS

0---2

When you are operating the engine or working near it,

use hearing protectors to avoid noise injuries.

In the service --- and repair work of the engine there is always the possibility of injury. Before starting the work
read and understand the following safety instructions
and remarks!

Stop the engine always before service --- or repair work.

Avoid touching the exhaust manifold, turbocharger and
the other hot parts of the engine.

Do not start a repair work that you do not fully handle.

Make sure that the place of the repair and the surrounding gives the possibility for safe working.
Always be sure of the cleanness and the good order of
the repairing place.
Do not use faulty or otherwise useless tools.
Remove all finger rings, chains and watch before starting work.
Use up ---todate protection equipment when you work.
For example eye protection as working with compressed air
for cleaning, grinding, hammering or other work.
Use lifting device for lifting and transporting heavy (over
20 kg) pieces. make sure of good condition of lifting hooks
and chains. The lifting ears on the engine must not be applied
by side forces when lifting.
Never work under an engine that is left handling under
a lifting device or lifted up by a jack. Always use strong supports before starting the work.
Use only genuine Sisudiesel spare parts.

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 the fuel system and batteries. (Specially when loading
batteries, explosive.)
Always disconnect the minus (---) wire of the battery
when doing service or repair of the electric system.
At temperatures on excess of 300C, e.g. if the engine
is burnt by a fire, the viton seals of the engine (e.g. the undermost o---ring of the oil pressure regulating valve) produce very
highly corrosive hydrofluoric acid. Do not touch with bare
hands, viton seals subjected to abnormally high temperatures. Always use neoprene rubber or heavy duty gloves and
safety glasses when decontaminating. Wash the seals and
the contaminated area with a 10% calcium hydroxide or other
alkali solution. Put all removed material in sealed plastic bags
and deliver them to the point stated by the Authorities concerned. NOTE! Never destroy viton ---seals by burning!
When checking fuel injectors do not let the jet of high
pressure fuel contact your skin. The fuel penetrates the skin
causing severe injuries. Contact your doctor immediately!
The fuel, lubricating oil and coolant cause irritation in
skin contact for long time.

Start the engine only by using the starting switch in the

cabin.
Do not start an engine if the protection covers are removed. NOTE! The fan is difficult to see as the engine is running! Make sure that wide clothes or long hear is not caught
in the rotating parts of the engine.
If you start the engine indoors, be sure you have proper
ventilation.
Never use aerosol type of starting aid while operating
the thermostart device (risk for explosion).

Avoid unnecessary idling of the engine.

Do not let oil and other liquids drop into the soil when
servicing the engine.

terial.

All the gaskets of the engine are of non ---asbestos ma-

Be careful when washing the engine with a high pressure washing machine. Do not use high pressure to wash e.g.
the electric and fuel equipment or the radiator because they
can easily be damaged.

Engine Specifications

0---3

ENGINE SPECIFICATIONS
320D 320DS

Engine type

Number of cylinders
3
3
3,3
3,3
Displacement (dm3)
Cylinder bore (mm)
108
108
Stroke (mm)
120
120
Compression ratio
Combustion
Firing order
1---2---3
Compression pressure bar1
275
280
Weight kg2
Direction of rotation
from the engine front
1)
2)

420D
4
4,4
108
120

335

420DS

420DW

4
4
4,4
4,4
108
108
120
120
16,5/18,5:1
direct injection
1---2---4---3
24
340
340

420DWI

620D

620DS

4
4,4
108
120

6
6,6
108
120

6
6,6
108
120

634DS
6
7,4
108
134

1---5---3---6---2---4
345

500

510

515

clockwise

Minimum value at operating temperature and starting revs. Max permitted difference between cylinders 3,0 bar.
Without flywheel and electrical equipment.

LIFTING 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

20--- 4

20--- 5

Engine weight: see Engine Specifications

LOCATION OF THE ENGINE SERIAL NO.

20--- 1

Special Tools

0---4

SPECIAL TOOLS
Order no

Description

3
4
5

9051 73100
9101 65600
9045 87600
9052 46400
9052 46300
9030 15200

Puller for cylinder liner

Milling cutter for cylinder liner seat
Spare cutting blade for milling cutter
Centring tool for flywheel housing
Drift for fitting rear crankshaft seal
Drift for fitting front crankshaft seal

6
7
8
9
10

9052 46620
9052 46650
9025 87400
9101 66300
9025 79200

Drift for 40 mm cup plug

Drift for 16 mm cup plug
Drift for fitting camshaft cup plug
Press tool for cylinder liner
Holder for dial gauge

11
12
13
14
15

9101 66100
9101 71100
9101 65502
9101 65503
9101 75800

T ---handle for valve seat milling cutter

Milling cutter for facing exhaust valve seat
Milling cutter for exhaust valve seat
Inner milling cutter for exhaust valve seat
Milling cutter for facing inlet valve seat

16
17
18
19
20

9101 65505
9101 65506
9101 66200
9052 47200
9101 66000

Milling cutter for inlet valve seat

Inner milling cutter for inlet valve seat
Lever for compressing valve spring
Counter nut for lever above
Milling tool for injector seat

21
22
23
24
25

9052 46660
9101 65800
9101 65900
9024 55800
9101 65700

Drift for 36 mm cup plug

Drift for removing valve guide
Drift for fitting valve guide
Spanner for crankshaft nut, 634---engines (620/MF/Steyr ---tractors)
Spanner for crankshaft nut

26
27
28
29
30

9052 48800
9020 01100
9052 46900
9025 98900
9025 98800

Puller for crankshaft gears

Conical sleeve for fitting pistons
Piston ring pliers
Drift for fitting dust cover, crankshaft front seal
Drift for fitting tension pin in timing gear casing

31
32
33
34
35

9025 98700
9101 93200
9104 27700
9050 40200
9051 79300

Drift for fitting tension pins in timing gear casing and flywheel housing
Coolant pump impeller extractor 620, 634
Coolant pump impeller extractor 320, 420
Fitting tool for coolant pump axial seal (seal 8353 31202)
Fitting tool for coolant pump axial seal (seal 8353 39425)

36
37
38
39
40

9051 64900
9052 47800
9052 48900
9025 99100
8366 62022

Fitting tool for coolant pump shaft 320, 420

Pressure valve testing gauge
Extractor for injection pump gear
Injection timing check pin (320, 420, 620, 634/Valtra Valmet---tractors)
Electronic timing kit

41
42

9025 99000
9051 71300

Control rod locking bush

Extractor for injector

1
2

Special Tools

0---5

4
9
11
10

15

12

18
13

16

19

26

17

14

24

22

21

23

20

27

29

25

28

32
30

31
39

38

41

33

34

35

42

36

37

40
20--- 6

Technical Data

0---6

TECHNICAL DATA
Cylinder block
Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing housing diameter (with bearing 8361 40950) . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder liner location, diameter:
--- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner diameter of camshaft bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height of cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13,250...13,320 mm
91,000...91,025 mm
92,000...92,025 mm
124,514...124,554 mm
123,000...123,040 mm
50,010...50,070 mm
428,170...428,430 mm

Cylinder liners
Protrusion of cylinder liner above cylinder block top face . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. permissible height difference between liners (under same head) . . . . . . . . . . . . . .
Outer diameter of cylinder liner guide:
--- at upper end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- at lower end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height of cylinder liner flange, 1st oversize, part no 8366 47933 . . . . . . . . . . . . . . . . . . . .
Height of cylinder liner flange, 2nd oversize, part no 8366 47934 . . . . . . . . . . . . . . . . . . .
Height of cylinder liner flange, 3rd oversize, part no 8366 47935 . . . . . . . . . . . . . . . . . . .
Outer diameter of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,030...0,080 mm
0,02 mm
124,475...124,500 mm
122,961...122,986 mm
108,010...108,032 mm
9,03...9,05 mm
9,08...9,10 mm
9,13...9,15 mm
9,23...9,25 mm
131,700...131,800 mm

Cylinder head
Height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height of cylinder head after repair grinding (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside diameter of valve guide (not fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . . . . . . . .
Depth of valve head face below cylinder head surface:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Angle of valve seat:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width of valve seat:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104,800...105,000 mm
104,000 mm
9,000...9,015 mm
16,028...16,039 mm
16,000...16,018 mm
21 mm

Diameter of exhaust valve seat ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

44,070...44,132 mm
44,000...44,025 mm
44,270...44,332 mm
44,200...44,225 mm

Diameter of inlet valve seat ring (8366 47936) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of inlet valve seat ring recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of inlet valve seat ring (overhaul part 8368 55347) . . . . . . . . . . . . . . . . . . . . . . .
Diameter of inlet valve seat ring recess (overhaul part 8368 55347) . . . . . . . . . . . . . . . . .
(See page 3---3)

48,570...48,632 mm
48,500...48,525 mm
48,770...48,832 mm
48,700...48,725 mm

0,70,05 mm (max. 2,20 mm)

0,60,05 mm (max. 2,20 mm)
35+20
45+20
2,9...3,7 mm
1,3...2,3 mm

Technical Data

0---7

Valves, rockers and tappets

With a valve clearance of 1,0 mm:
--- inlet valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- inlet valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve clearance cold and hot:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Angle of valve seat in cylinder head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width of valve seat in cylinder head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Angle of valve face:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outside diameter of valve head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max valve movement:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside diameter of valve guide before fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protrusion of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . . . . . .
Depth of valve face below cylinder head surface:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring pressure when spring compressed to a length of:
--- 48,6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 37,4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside diameter of rocker arm bearing bush:
--- (when fitted in position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outside diameter of rocker arm bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. permissible push rod deflection (when free) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free length of rocker arm spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring pressure when spring compressed to a length 58 mm . . . . . . . . . . . . . . . . . . . . .
Outside diameter of tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of tappet bore in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engines from 96 week 34
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02 B.T.D.C
162 A.B.D.C
392 B.B.D.C
12 A.T.D.C
0,35 mm
0,35 mm
35+20
45+20
2,9...3,7 mm
1,3...2,3 mm
35 ---20
45 ---20
48 mm
41 mm
10,9 mm
12,1 mm
8,960...8,975 mm
8,925...8,940 mm
0,025...0,055 mm
0,30 mm
0,060...0,090 mm
0,35 mm
9,000...9,015 mm
16,028...16,039 mm
16,000...16,018 mm
21 mm
0,70,05 mm (max. 2,20 mm)
0,60,05 mm (max. 2,20 mm)
69,8 mm
32717 N
50023 N
19,959...19,980
19,990...20,010 mm
23,035...23,075 mm
23,000...23,021 mm
0,4 mm
80 mm
80...100 N
29,939...29,960 mm
30,000...30,043 mm
22,970...22,990 mm
23,000...23,021 mm

Camshaft
Diameter of camshaft bearing journal no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of camshaft bearing journals (others that no 1) . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of camshaft bearing journals nos 2, 3 and 4 (620/634---engines) . . . . . . . . . . .
Inside diameter of camshaft bearing bushes (when fitted in position) . . . . . . . . . . . . . . .
Diameter of camshaft bearing bores (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft clearance in bearing bush no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49,925...49,950 mm
49,885...49,910 mm
49,865...49,890 mm
50,010...50,070 mm
50,000...50,025 mm
0,060...0,145 mm

Technical Data
Camshaft clearance in bearing bushes (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft clearance in bearing bushes nos 2, 3 and 4 (620/634---engines) . . . . . . . . . . .
Bearing bush tolerance in block (press fit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of bearing bush bore in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft end play with 0,5 mm gasket between cylinder block and timing gear
housing and between timing gear housing and front cover . . . . . . . . . . . . . . . . . . . . . . . .
Cam height (distance between back of cam and tip of cam):
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam lift:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft max. permissible deflection (total indicator reading) . . . . . . . . . . . . . . . . . . . . .

0---8

0,090...0,140 mm
0,110...0,160 mm
0,025...0,080 mm
55,620...55,650 mm
0,5...1,0 mm
41,180...41,430 mm
40,080...40,330 mm
7,38 mm
8,28 mm
0,03 mm

Crankshaft
Crankpin diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 1. undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 2. undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 3. undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 4. undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankpin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67,981...68,000 mm
67,731...67,750 mm
67,481...67,500 mm
66,981...67,000 mm
66,481...66,500 mm
40,000...40,160 mm

Main bearing journal diameter:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 2nd undersize 0,50mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing housing diameter (in cylinder block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84,985...85,020 mm
84,735...84,770 mm
84,485...84,520 mm
83,985...84,020 mm
83,485...83,520 mm
91,000...91,025 mm

Main bearing shell thickness:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- bearing 8361 40950 (see page 5---1 instruction B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2,955...2,965 mm
3,080...3,090 mm
3,205...3,215 mm
3,455...3,465 mm
3,705...3,715 mm
3,705...3,715 mm

Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Length of thrust bearing journal (journal nearest to flywheel):
--- standard (2 standard thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 1st oversize (one std and one 0,1 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . .
--- 2nd oversize (one std and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . .
--- 3rd oversize (one 0,1 mm and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . .
--- 4th oversize (two 0,2 mm overthick thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,050...0,127 mm
45,000...45,080 mm
45,100...45,180 mm
45,200...45,280 mm
45,300...45,380 mm
45,400...45,480 mm

Other crankshaft journals may not be ground longer.

Crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. permissible ovality and other deformity of crankpins or journals . . . . . . . . . . . . . . .
Crankshaft unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing unit ring gear location, diameter (420---engines) . . . . . . . . . . . . . . . . . . . . . . . .
Balancing unit ring gear I.D. (420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,100...0,380 mm
0,03 mm
1,0 Ncm Max.
150,220...150,260 mm
150,000...150,040 mm

Flywheel
Flywheel ring gear no. of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interference fit between ring gear ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before fitting the ring gear, heat up to a temperature of . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max permissible axial wobble of flywheel clutch face, measured at inner edge
of clutch face on diameter 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133 pcs
0,425...0,600 mm
150...200C
1,0 Ncm Max
0,06:200

Technical Data

0---9

Balancing unit (420---engines)

Tooth backlash:
--- crankshaft ring gear ---balancer weight gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- between the balancer weights gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing weights end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft diameter at bearing surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing bushing inner diameter (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of holes in body for shafts, rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of holes in body for shafts, front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shim thickness, cylinder block ---balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,1...0,3 mm
0,05...0,250 mm
0,1...0,5 mm
36,000...36,016 mm
36,050...36,075 mm
36,058...36,083 mm
35,958...35,983 mm
0,2 mm

Timing gears
Tooth backlash:
Crankshaft---idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler gear ---camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler gear ---fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. permissible side wobble of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner diameter of idler gear bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner diameter of Idler gear hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft gear hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft end diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,05...0,25 mm
0,05...0,25 mm
0,05...0,25 mm
0,05 mm
54,951...54,970 mm
55,000...55,030 mm
60,000...60,030 mm
32,000...32,025 mm
32,043...32,059 mm

Timing marks:
Timing marks on gears are in alignment when the 1st cylinder piston is at its top dead centre
between compression and power strokes.
On crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On idler gear:
--- against crankshaft gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- against camshaft gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- against fuel injection pump gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 dots on tooth
0 on tooth
1 dot on tooth
1 dot on notch
1 dot on notch
1 dot on tooth

Connecting rod
Inside diameter of piston pin bush (with bush pressed into connecting rod) . . . . . . . . . .
Outside diameter of piston pin bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outside diameter of piston pin bush (oversize 8353 28326) . . . . . . . . . . . . . . . . . . . . . . . .
Interference fit: connecting rod small end bushing ---connecting rod . . . . . . . . . . . . . . . .
Connecting rod small end bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod small end bore (oversize bush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod big end bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Big end bearing shell thickness:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Big ---end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End float (side clearance) at big ---end on crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston pin bushing location perpendicular to longitudinal axis of connecting
rod to be within . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston pin bushing location and big ---end bearing location to be parallel to within . . . . .
Weight marking (letter) at lower end.
Max. permissible weight difference between connecting rods in the same engine . . . . .
Position of connecting rod; weight marking at valve mechanism side
(away from the combustion chamber in the piston)

40,025...40,040 mm
44,080...44,120 mm
44,580...44,620 mm
0,057...0,120 mm
44,000...44,025 mm
44,500...44,525 mm
71,730...71,749 mm
1,835...1,842 mm
1,960...1,967 mm
2,085...2,092 mm
2,335...2,342 mm
2,585...2,592 mm
0,046...0,098 mm
0,200...0,410 mm
0,15:100
0,05:100
20 g

Technical Data

0---10

Piston, rings and pin

Minimum distance between piston and cylinder head (measured with a piece
of lead wire thought the injector location hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston diameter:
--- 17 mm from lower edge (320, 420, 620---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 19 mm from lower edge (634---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin bore in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,900...1,150 mm
107,873...107,887 mm
107,883...107,897 mm
40,003...40,009 mm
39,991...40,000 mm

Width of ring grooves:

--- 1st groove (right---angled ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,560...2,580 mm
--- 2nd grove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,520...2,540 mm
--- 3rd groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,040...4,060 mm
Side clearance of piston rings in their grooves:
--- 1st ring (right---angled ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,07...0,102 mm
0,03...0,062 mm
0,05...0,082 mm
0,15 mm

Piston ring height (in direction of cylinder):

--- 1st ring (right---angled ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,478...2,490 mm
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,478...2,490 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,975...3,990 mm
Piston ring gap (with piston fitted in cylinder)
--- 1st ring (wedge shaped ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 1st ring (right---angled ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- reject limit 1st and 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- reject limit 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,40...0,55 mm
0,30...0,45 mm
0,60...0,80 mm
0,30...0,60
1,0 mm
1,5 mm

Max. permissible weight difference between pistons in same engine . . . . . . . . . . . . . . . . . 25 g

Piston to be heated up to 100C before fitting gudgeon pin.
Piston position in cylinder: combustion chamber of piston to face towards injector.

Lubricating system
Oil pressure at normal running temperature:
--- at idling speed (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- at running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free length of oil pressure valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring pressure when valve spring is compressed to a length of 52 mm . . . . . . . . . . . . .
Diameter of oil pressure valve plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of oil pressure valve cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter by ---pass valve opens at a pressure difference of . . . . . . . . . . . . . . . . . . . . . . . . . .

100 kPa (1,0 kp/cm2)

250---400 kPa(2,5---4,0 kp/cm2)
80 mm
54+5 N (5,4+0,5 kp)
19,602...19,635 mm
19,700...19,752 mm
20,5 kp/cm2

Oil pump (320, 420---engines)

Backlash between gears when crankshaft lies firmly against the lower side of main bearings:
--- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
--- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,16...0,26 mm
Diameter of drive shaft at bearings for body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,966...17,984 mm
Diameter of shaft holes on body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000...18,018 mm
Diameter of gear wheel hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,060...18,078 mm
Fixed shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,028...18,039 mm
Protrusion of fixed shaft end below pump body face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5...1,0 mm
Thickness of cover gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06...0,08 mm

Technical Data
Outside diameter of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End play of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Depth of housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of teeth on drive gear (320---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of teeth on drive gear (420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0---11

43,486...43,525 mm
43,650...43,750 mm
24,000...24,027 mm
0,03...0,11 mm
24,000...24,043 mm
51 pcs
46 pcs

Oil pump (620/634---engines)

Backlash between gears when crankshaft lies firmly against the lower side of main bearings:
--- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
--- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,16...0,26 mm
Diameter of drive shaft at bearings for body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,966...17,984 mm
Diameter of drive shaft bearing hole on body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000...18,018 mm
Hole diameter of gear pressed on drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,060...18,078 mm
Diameter of fixed shaft at gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,966...17,984 mm
Inner diameter of bearing for gear wheel which rotates on fixed shaft . . . . . . . . . . . . . . . . 18,000...18,018 mm
Fixed shaft in pump body, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,035...20,048 mm
Protrusion of fixed shaft end below pump body face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5+0,5 mm
Thickness of cover gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06...0,08 mm
Outer diameter of gear wheels (620---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,486...43,525 mm
Outer diameter of gear wheels (634---engines/620---engines J 7891>) . . . . . . . . . . . . . . . 55,824...55,870 mm
Housing diameter (620---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,650...43,750 mm
Housing diameter (634---engines/620---engines J 7891>) . . . . . . . . . . . . . . . . . . . . . . . . . 56,000...56,120 mm
Thickness of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,000...32,027 mm
End play of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03...0,11 mm
Depth of housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,000...32,043 mm
Number of teeth on drive gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 pcs

Coolant pump (320, 420---engines)

Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside diameter of bearing housing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of the seal recess in the pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The impeller is pressed onto the shaft until the distance between
the rear face of impeller and the rear face of the pump body is . . . . . . . . . . . . . . . . . . . . .
Distance of belt pulley from rear face of body:
--- 320; <E 7535, 420; <E 7054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 320; E 7536>, 420; E 7055> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan guide diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing precision of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. permissible eccentricity of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38,087...38,100 mm
38,058...38,083 mm
15,910...15,920 mm
15,881...15,899 mm
36,450...36,489 mm
1,8...2,2 mm
178,3...178,7 mm
174,4...174,6 mm
25,00...25,20 mm
0,3 Ncm max.
0,3 mm
15...20 mm

Coolant pump (with separate ball bearings 320 --- and 420 ---engines)
Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft diameter at bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft diameter at impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller should be pressed onto shaft inside the housing . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of fan hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. permissible eccentricity of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The fan belt tension pushing from the middle,
deflection from the line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 mm
51,979...52,009 mm
20,002...20,015 mm
15,907...15,920 mm
15,881...15,899 mm
1,8...2,2 mm
0,3 Ncm max. (30 pcm)
0,3 mm
15...20 mm

Technical Data

0---12

Coolant pump (620/634---engines)

Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside diameter of bearing housing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft diameter at bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft diameter at impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of the seal recess in the pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distance between impeller and rear face of pump body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing precision of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 mm
51,979...52,009 mm
19,980...19,993 mm
15,907...15,920 mm
15,881...15,899 mm
36,450...36,489 mm
0,8...1,2 mm
0,3 Ncm max (30 pcm)
15...20 mm

Pump equipped with reinforced bearing:

Outer diameter of the front bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 mm
Bearing up diameter in water pump wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95,000...95,035 mm
Outer diameter of bearings position in pump frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59,991...60,009 mm

Thermostat
Spare part number

Type

Opening
begins at

Fully
open at

Max. stroke
mm

8361 15646
8361 15718
8366 59685
8360 15156
8363 31590

67/79C
67/83C
67/86C
54/79C
67/83C

792C
832C
862C
792C
832C

94C
97C
99C
94C
95C

8
8
8
7,5
8

Turbocharger
Schwitzer S1A (320 DS)
Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft radial clearance 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schwitzer S1B (420 DS) and S1BG by -- pass turbo (420DW)

Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft radial clearance1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
By ---pass passage opening pressure (S1BG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schwitzer S2B (620/634 DS) and S2BG by -- pass turbo (620/634DW)

Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft radial clearance1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut on end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1)

Measured at nut on end of shaft.

max. 0,14 mm
max. 0,61 mm
22 Nm
6,8 Nm
max. 0,14 mm
max. 0,51 mm
22 Nm
8,1 Nm
1,035 bar

max. 0,14 mm
max. 0,95 mm
17 Nm
15,6 Nm

Tightening Torques

0---13

TIGHTENING TORQUES
Object

Nm

Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm+90+90 (see page 3--- 4)

Cylinder head studs to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm + 90
Crankshaft nut:
--- 320/420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
--- 620/634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Crankshaft counterweight, 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Crankshaft pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Flywheel bolts, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Flywheel bolts, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Flywheel housing bolts:
--- outer ring M12, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
--- outer ring M12, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
--- inner ring M10, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
--- inner ring M10, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Idler gear bolts:
--- M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
--- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Idler gear retaining screws (with ball bearing):
--- the bigger bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
--- the bolts for holding the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Balancing weights, 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Piston cooling valve (620/634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil pump gear nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil pump retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil cooler connecting piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Coolant pump pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Fan bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Intake manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Injection pump pressure valve holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Injection pump gear retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Injection pump gear retaining nut (Bosch ---P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Compressor pulley nut (Knorr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Always use the torque values listed in the following tables when specific torque values are not available.
M8

M10

Cast iron

355 Nm

705 Nm

Aluminium

255 Nm

505 Nm

Use a washer with the aluminium parts.

The bolts of a self carrying oil sump
1
2
21
3
4
5
6
6
1)

M8
M10
M12
M14
M20
M16
M20
M22

12.9
12.9
12.9
10.9
10.9
10.9
10.9
10.9

320 and 420

30 Nm
90 Nm
150 Nm
200 Nm
700 Nm
300 Nm
700 Nm
700 Nm

Construction

0---14

CONSTRUCTION
General
The Sisudiesel 20/34---series engines (3---, 4---, or 6---cylinders) are water ---cooled, four stroke, direct---injection in ---line
diesel engines. All engines are produced as naturally aspirated engines, turbocharged engines and the four --- and six
cylinder engines also as intercooled.

The flywheel housing are delivered according to the requirements set, by the engine application and differet flywheel
housings can be mounted on all engine types.

The engines have a rigid and ribbed cylinder block. The crank
mechanism is designed for supercharging. The cylinder
liners are wet and supported at the middle. The cylinder head
bolts are high tensile bolts.

Cylinder block
The cylinder block is the main body of the engine, to which
other engine parts are attached. Wet and replaceable cylinder
liners are supported at the middle which reduces vibrations
and directs coolant circulation mainly to the upper part of the
liners.
The seal between the cylinder liner lower part and the cylinder
block is achieved by three o---rings, which are fitted in grooves
in the liner. The upper part is sealed by the cylinder head
gasket.
The camshaft is located in the cylinder block. The camshaft
front bearing location is fitted with a separate bearing sleeve.
The remaining bearing locations are machined directly in the
cylinder block. The latest 620/634---engines have separate
bearing sleeves in all camshaft bearing locations. 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 housing
The flywheel housing is fitted at the rear end of the cylinder
block. The seal for the crankshaft rear end is placed in a bore
in the housing. The starter motor fixing point is fitted in the flywheel housing.
The lower face of the flywheel housing functions as a sealing
surface for the oil sump gasket. This means that the lower face
of the cylinder block must be level with the flywheel housing.
When fitting the flywheel housing, its position is determined
by tension pins.

20--- 7

Construction

0---15

Crank mechanism
The crankshaft is forged from chrome alloy special steel and
is induction hardened at the bearing and sealing surfaces.
This makes it possible to grind bearings four times without a
new heat treatment. Gear wheels are located 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 crankshaft has
splines for the hub of the V ---belt pulley. An oil deflector ring
is fitted between the hub and gear wheel, and a dust shield is
fitted on the hub in order to protect the seal.
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 bearing more than cylinders. The
crankshaft thrust washers are placed in both sides of the rearmost main bearing.
At the rear end of the crankshaft there is fitted a flywheel on
which is a press---fit a starter ring gear. The forged connecting
rod has an I ---section cross---section. The bearing location at
the bottom end of the connecting rod is split, and the bearing
cup is secured by two special bolts and nuts. The upper part
has a wedge ---shaped bearing location, in which the piston
pin bearing bushing is fitted with a press fit.
20--- 8

Cylinder head
320--- and 420---engines have one cylinder head.
620/634---engines have two cylinder heads which are exchangeable with each other and also with the cylinder head
on the 320---engine. Each cylinder has its own inlet and exhaust ports located on either side of the head. Between hot exhaust valves a cool inlet valve is fitted to balance the thermal
load.
Cylinder head bolts are high tensile bolts which are tightened
up to yield limit using angle tightening principle. Due to the
large stretch the tightening forces are kept constant during the
whole lifetime and retightening is unnecessary.
The injector locations are machined directly into the cylinder
head. The inlet and exhaust valve guides are identical and can
be interchanged. In addition, the exhaust valves are equipped
with replaceable valve seat inserts.

Valve mechanism
The valve mechanism is operated by the camshaft which is located in the cylinder block. The drive is transferred with the
help of tappets and pushrods. The camshaft gear wheel is
fitted with a press fit and fixed with a key. Each bearing is lubricated by the force feed lubrication system through drilled oilways in the motor block.

The piston is made of an eutectic aluminium alloy. In the

upper face of the piston there is a combustion chamber. The
shape of the chamber is intended to maximise the mixture of
air and fuel. The piston has three rings. The upper molybdenum ---coated ring has a wedge ---shaped cross---section.
On natural aspirated engines and on slight supercharged engines the upper ring is right---angled. The middle ring is tapered and it fits into its groove. The taper taking up the clearance. The oil control ring is spring loaded and it has a
two---stage, chromed scraping edge.
On the turbocharged engines the upper ring location is
formed in a cast iron ring which is cast in the piston. In addition, the piston on supercharged engines is graphite coated
to ensure correct running ---in.
Four ---cylinder engines (420) are equipped with a balancer
unit. The eccentric weights, which rotate at twice the engine
speed, even out the vibration forces exerted by the movement
of the pistons and the crank mechanism.

Construction

0---16

20--- 9

Timing gears
The timing gear train consists of hardened, helically cut gear
wheels. The gears are encased by the timing gear casing
which is fitted to the front of the engine. The timing gear drives
the camshaft, fuel injection pump and oil pump.
If the engine is equipped with a hydraulic pump, it is driven via
a gear or a separate drive unit.
The idler gear is supported with a bearing sleeve/ball bearing
(620/634) on the shaft on the front face of the cylinder block.
Two different dimensions of gear and shaft is used.

Construction

0---17

1
20--- 10

Lubricating system (620/634-- engines)

1. Lubricating oil pump
2. Pressure ---relief valve
3. Oil filter
4. Turbocharger
5. Main oil gallery
6. Piston cooling nozzle
7. Oil pressure sensor

Lubricating system
The engine has a pressure lubricating system in which the oil
pump (gear pump) is attached to the cylinder block lower
face. The oil is sucked up by the pump through a suction
strainer. After the pump the oil is led through an oilway to the
relief valve and to the oil filter. After the filter, the oil is led
through the main oil gallery from which oilways branch out.
The oil is led through the oilways in the main bearings and
through the crankshaft to the big ---end bearings.
The oil is further directed from the main gallery to the injection
pump, turbocharger, balancing unit (420) and to a possible
compressor. In addition, the idler gear bushing, the camshaft
bearing points and the valve mechanism get their lubrication
oil via the main oil gallery.
In 620/634---engines, with high power rating, is the bottom of
the piston cooled with oil spray always when the oil pressure
is higher than 3 bar.

The oil pressure relief valve is located under the oil filter on the
left hand side of the engine. The valve regulates the lubricating oil pressure so that it is kept constant, regardless of the engine speed. Oil pressure is about 2,5 ---4 bar depending on
revs, oil quality and temperature, and at engine idling speed
the pressure is min 1,0 bar.
The oil filter is full---flow disposable type and is fitted on the
left---hand side of the engine. A by ---pass valve is located at
the base of the filter to ensure safe cold ---starting or to ensure
adequate lubrication in case the filter becomes blocked. In
addition, there is a non ---return valve which stops the filter
from being emptied of oil.

Construction

0---18

2
3

6
1

The cooling system

1. Coolant pump
2. Thermostat
3. By ---pass pipe
4. Radiator
5. Expansion tank
6. Oil cooler

Cooling system
The belt driven, centrifugal type coolant pump is attached at
the front end of the cylinder block and the thermostat housing
is fitted above the pump. The system has an internal coolant
circulation via the by ---pass passage and the circulation is
controlled by a two---way thermostat. With this is achieved an
even warming in all conditions.
The coolant pump has separate ball bearings or the pump
shaft and the bearings are built together to form one unit
(320--- and 420 engines).
The thermostat opens at 79C. During a cold season, a thermostat with the opening temperature of 83C can be use.

20--- 11

In some 620/634---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 circulates through the by --pass hole into the coolant pump. The smaller, singleacting
thermostat opens first (at 79C) letting one part of the coolant
into the radiator. Following the load increase, also the other
thermostat opens (at 83C). This is a double ---acting type
which closes the by ---pass hole when it opens and directs the
coolant into the radiator. These engine models do not have
any separate winter ---type thermostats.

B
A
20--- 12

Construction

0---19

20--- 13

Inlet and exhaust system

The filter system for the engine inlet air comprises a cyclone
type precleaner, and a paper filter which acts as the main filter.
The incoming air is made to rotate in the cyclone precleaner.
This causes most of the impurities to settle out and collect in
the cyclone precleaner dust collector. The paper filter comprises one or two replaceable filter elements. The paper is
corrugated and surrounded by a metal support.
The impurities in the air collect at the larger filter element
which can be cleaned when necessary. The inner safety filter
prevents impurities form entering the engine should the main
filter element break, or be fitted incorrectly.
A mechanical or electrical service indicator can be mounted
on the filter housing or on the inlet pipe to show when the filter
cartridge is clogged. The inlet system also includes the hoses
between the air cleaner and the turbocharger and the turbocharger and the intake manifold.

20--- 13/1

The exhaust manifold is attached to the cylinder head with

high tensile bolts without a separate gasket. Retightening of
the manifold bolts is unnecessary.
In the marine --- and generator engines a liquid cooled exhaust
manifold is used, that is connected to the engines cooling
liquid circulation (so---called freshwater circulation). These
exhaust manifolds are sealed from the liquid circulation part
with o---rings in 420---engines and with level seals in
320/620/634---engines.
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 lubricated and cooled by the lubrication system of the engine.
DW/DWI engine is equipped with a by ---pass turbocharger
where the highest air pressure is adjusted by so---called by --pass channel.

The compressed air is cooled by the air to water basis. The air
coming from the turbocharger has a temperature about
150C which is cooled by the cooling water of the engine
down to about 95C.
The cooling cell is installed on the intake manifold and connected to the engine cooling system. The cooling of the compressed air stabilised the combustion, irrespective of the temperature, and minimises the thermal and mechanical load of
the engine thus lowering nitric oxides (NOx).

Construction

20--- 14

Electronic Engine Management system (EEM)

The Sisudiesel EEM system is a microprocessor based diesel
engine control system to replace the traditional mechanical
speed governor on the engine. This system significantly improves the properties of the engine and adds several functions and operational features that could not be realised with
mechanical governors. The EEM system is applicable to all
kinds of vehicles, on --- or off ---road.
The system consists of the following components:
---------

Fuel injection pump with electrical actuator system

Electronic control unit
Sensors for engine parameters and speed demand value
Wiring harness

0---20

Cylinder Block

1---1

WORK INSTRUCTIONS
1. CYLINDER BLOCK
A. Measuring cylinder liner wear

9051 73100

1. Using a micrometer set the dial gauge to zero using a new

cylinder liner indicating the initial dimension of the bore:
108,00 mm.
2. Clean the inner surface of the cylinder liner thoroughly before measurement.

21--- 2

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.
21--- 1

3. Perform the measurement crosswise at the liner top end,

lower end and middle.
4. Check the gauge reading for maximum wear and ovalness
(compare with rated).

B. Removing cylinder liner

1. If the cylinder liners are to be used again they should be
marked so that they can be fitted in the same position.
2. Remove the cylinder liners using cylinder liner puller 9051
73100.

4. Measure the wear of the camshaft bearing points (compare

with rated).
Note! If it is necessary to machine the upper face of the cylinder block, the pistons must be shortened by the same dimension. Observe the valve disc spaces on the piston upper face.

D. Changing camshaft bushing

1. Extract the bushing with an internal puller, for example
Sykes 854. If the camshaft rear end plug is removed the bushing can be forced out with a long drift.
2. Clean the bushing location carefully.

Cylinder Block

1---2

30
0,1...0,4 mm

21--- 3/1

21--- 3

3. Press in a new bushing. 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.
Note! On the 620--- and 634---engines from the engine ser.
number C2751, all camshaft bearing points are provided with
a separate bearing bushing. Observe the different outer diameters when removing and fitting.

Note! From engine number L 13188 the cam shaft front end
bushing is equipped with the 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).

1
21--- 4

Order numbers of the camshaft bushings and hole diameters

for the bushings on the 620/634---engines.
Note! Numbering begins from the front end of the engine.

Order no.

Hole diameter

1. 8363 22610
2. 8368 52460
3. 8368 52459
4. 8368 52460
5. 8368 52461

55,62...55,65
55,42...55,45
55,22...55,25
55,42...55,45
55,64...55,67

E. Oversize bushings for camshaft

If the location of the camshaft bushing (front bearing) is damaged, a bushing with a 0,4 mm oversize outer diameter can
be fitted. Bushings are available even for other camshaft bearings which do not normally have bushings. Part numbers and
machining dimensions for the bushing locations are shown in
the figure.
Observe the position of the bushing oil holes. It is unnecessary to ream the bushings after fitting.

140 mm

134 mm

6...7 mm

1
21--- 5

Oversize camshaft bushings for 320---engines. Numbering

begins from the front end of the engine.
Order no.

Hole diameter

1. 8363 24661
2. 8368 52460
3. 8368 52460
4. 8368 52461

56,02...56,05
55,42...55,45
55,42...55,45
55,64...55,67

Cylinder Block

1---3

134 mm

272 mm
6...7 mm

1
21--- 6

Camshaft oversize bearing bushings for 420---engines.

Numbering begins from the front end of the engine.

Order no.

Hole diameter

1. 8363 24661
2. 8368 52460
3. 8368 52460
4. 8368 52461

56,02...56,05
55,42...55,45
55,42...55,45
55,64...55,67

266 mm
272 mm

134 mm

6...7 mm

21--- 7

Camshaft oversize bearing bushings for 620/634---engines.

Numbering begins from the front end of the engine.

Order no.

Hole diameter

1. 8363 24661
2. 8368 52466
3. 8368 52460
4. 8368 52466
5. 8368 52467

56,02...56,05
55,62...55,65
55,42...55,45
55,62...55,65
55,84...55,87

F. Fitting plug at camshaft rear end

1. Clean the seat for the plug.
2. Apply sealing compound to the contact surface of the plug

max. 1,0 mm

21--- 8

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 the blocking plug.

21--- 9

3. Drive in the plug with fitting drift 9025 87400.

Note! Do not drive in the plug too far because it will affect the
camshaft end float.

Cylinder Block
G. Fitting guide pipe for oil dipstick
1. Clean the seat for the pipe.
2. Apply locking fluid Loctite 601 to the lower end of the guide
pipe.

1---4

3. If the recess is damaged, or the cylinder liner height (see

point 5) needs to be adjusted, use milling cutter 9101 65600.
If necessary, a light lapping can be executed after milling with
the help of the cylinder liner. Apply lapping paste to the underside of the cylinder liner flange, and twist the liner with twisting
tool. Lapping is not suitable for adjusting the cylinder liner
height.
4. Clean the contact surfaces.
9101 65600

21--- 10

3. Tap the guide pipe in its position at the level indicated in the
picture.

9025 95900

20--- 12

0,03...0,08 mm
9025 79200

21--- 11

4. Tap the guide pipe 8361 29747 (bent pipe) in to the correct
fitting height with tool 9025 95900.
Note! The position of the guide pipe affects an oil level in the
engine.

H. Fitting cylinder liner

1. Clean the cylinder liner and its recess in the cylinder block.
Without o---rings the liner should rotate easily in its recess.
2. Apply a thin layer of marking paint on the underside of the
cylinder liner flange. Fit the cylinder liner without o---rings and
turn it forwards and backwards. Lift out the liner and check
that paint has been deposited on the whole contact surface.

9101 66300
20--- 13

5. Fit the cylinder liners and fix each liner with two press tools
910166300. Measure 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 cylinder block face should be 0,03...0,08 mm. The height difference between cylinder liners under the same cylinder head
must not exceed 0,02 mm, nor must an intermediate cylinder
liner lie lower than an outer one.

Cylinder Block

1---5

6. If the cylinder liner height is too low, a liner with a higher

flange is fitted.

21--- 14

Order no

Markinggrooves
pcs

8366 47420
8366 47933
8366 47934
8366 47935

9,03+0,02
9,08+0,02
9,13+0,02
9,23+0,02

--- (std.)
1
2
3

Cylinder liners with oversize flanges (higher flanges) are

marked with grooves on the outer circumference as follows:
1st oversize, 0,05 mm = 1 marking groove
2nd oversize, 0,10 mm = 2 marking grooves
3rd oversize, 0,20 mm = 3 marking grooves
Note! Recess depth is adjusted with a cylinder liner recess
cutter 9101 65600.
7. If the liner height of a cylinder liner is not the same all the way
round, the cylinder liner flange and the cylinder block recess
depth should be checked. Cylinder liners with warped flanges
should be discarded.

Musta/Black/Svart/Schwarz
Vihre/Green/Grn/Grn

21--- 15

8. Fit the o---rings into the grooves in the cylinder lower part
and lubricate them with a liquid soap (not with engine oil).
Note! Stretch the o---rings as little as possible when fitting
them. Max allowable stretching is 6 %.

21--- 16

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.

Flywheel Housing

2---1

2. FLYWHEEL HOUSING

A. Fitting flywheel housing

The flywheel housing is centred on the cylinder block by two

tension pins. Even the flywheel housings which are delivered
as spare parts have ready ---made holes for the pins.
1. Clean the sealing surfaces between the cylinder block and
the flywheel housing.

22--- 2

B. Changing crankshaft rear oil seal

1. Lift out the engine. Remove the clutch assembly (and possible turbine clutch).
2. Remove the flywheel.
3. Remove the oil seal. Do not damage the crankshaft.
4. Clean the seal location and grind off any burrs.
22--- 1

2. Apply silicone sealant as shown in figure above.

3. Lift the flywheel housing into place and fit all the bolts.
4. Centre the housing with centring tool 9052 46400 (Note!
This is important of the engines with a turbine clutch) and fit
the tension pins with drift 9025 98700.
5. Tighten the fixing bolts, the inner ring socket head bolts to
60 Nm (8.8) / 80 Nm (12.9) and outer ring hexagonal bolts to
110 Nm. (8.8) / 150 Nm (12.9)
NOTE! MODIFICATION OF THE FLYWHEEL HOUSING
All the below mentioned flywheel housings have been in the
inner circle added with 3pcs 11 mm holes (E) and in in the
outer circle with 1 pcs 13 mm hole (A). Under the bolts in the
added holes has to be added a spring washer 10 mm, order
no. 5009 51000, 3 pcs (E) and 12 mm, order no. 5009 51200,
1 pc (A).
The modified flywheel housings:
8363 46658
8366 47441
8366 47440
8366 47442

22--- 3

Note! If the crankshaft is worn at the sealing location, a 2 mm

spacer ring, part no. 8360 20054, can be fitted in front of the
crankshaft rear oil seal.

Flywheel Housing
5. Fit the seal as follows:
--- Do not remove the plastic sleeve in before hand.
--- NOTE! FIT THE SEAL DRY, NOT OILED!

O = Sleeve
T = Seal

22--- 4

--- 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.

9052 46300

22--- 5

--- Remove the sleeve and hit the seal into position with the fitting tool 9052 46300.

2---2

Cylinder Head

3---1

3. CYLINDER HEAD

C. Checking cylinder head

A. Removing cylinder head

1. Remove the soot from the exhaust ports, clean the sealing
surfaces and wash the cylinder head.

1. Clean the engine externally and drain the coolant. Disconnect the coolant hoses from the cylinder head and the thermostat housing.

2. Check for cracks and other damage.

2. Remove the suction hoses between the turbocharger and

the air filter and between the turbocharger and the inlet manifold.
3. Disconnect the turbocharger pressure and return oil pipes.
4. Remove the pipes to the thermostart fuel reservoir.
5. Remove the injector leak ---off fuel pipes and the delivery
pipes. Remove the injectors. Fit blanking ---off caps on all
open connections.
23--- 2

6. Remove the inlet and exhaust manifolds and the thermostat

housing.
Note! It is possible to remove the cylinder head even thought
these parts are attached to the head.
7. Remove the valve cover and the breather hose.
8. Remove the rocker arm mechanism and the push rods.

3. Check the flatness of the cylinder head by using a straight

edge. An uneven or warped surface should be surface
ground. The height of the cylinder head, after grinding, should
not be less than 104,00 mm. The valve disc depth from the
cylinder head surface should be 0,60 mm for the exhaust
valves and 0,70 mm for the inlet valves.

9. Loosen all the cylinder head bolts first by a 1/4 turn and then
remove them. Remove the cylinder head.

B. Removing valves

9101 66000

Ensure that valves which are to be re ---used are marked, so

that they are fitted in their original locations.
9052 47200
9101 66200

23--- 3
23--- 1

1. Install the counter screw 9052 47200 for the valve spring installing tool in the rocker arm cover bolt. On the 320--- and
620/634---engines there is not a screw stud at the valves for
the centre cylinder. A bolt of suitable length should be used
instead.
2. Compress the valve springs using lever 9101 66200. Remove the valve cotters, spring guide and spring. Remove the
valves.

4. Straighten and clean the injector location seat in the cylinder head with cutter 9101 66000.

Cylinder Head

3---2

9101 65900

23--- 6

23--- 4

5. Measure the clearance between the valve stem and the

valve guide with a dial gauge. Lift the valve so that the valve
head is 15 mm from the face of the cylinder head, and
measure the clearance. It must not be greater than 0,30 mm
for the inlet valves and 0,35 mm for the exhaust valves. In
order to establish the valve guide wear, a new valve should be
used when measuring.
23--- 7

D. Changing valve guides

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.

9101 65800

E. Machining valve seat

9101 66100

23--- 5
23--- 8

1. Press or knock out the old guides using 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).

Machine the damaged valve seat with milling cutter. If the

width of the seat exceeds 2,3 mm in exhaust and 3,7 mm in
intake, it should be reduced primarily at the outer edge.
The valve seat angle is 45+20 for exhaust valve and 35+20
for inlet valve.

Cylinder Head

3---3

F. Changing valve seat rings

G. Grinding valves

Exhaust valves are fitted with separate valve seat rings. If the
sealing surface is damaged so badly that it cannot be repaired
with machining, the seat ring should be changed.

In order to ensure that there is a proper seal around the valves,

there is a difference in the sealing surface angles. Thus there
is a very narrow sealing surface which seals effectively even
after prolonged running.

1. Grind the valve head on a discarded valve so that it sits

down in the valve seat. Fit the valve and weld it in place in the
seat. Cool with water.
2. Turn the cylinder head over and knock out the valve and
seat.

3. Clean the valve seat location. Cool the new seat ring in liquid
nitrogen until it stops bubbling, or alternatively place it in dry
ice.

A
C

4. Fit the seat with a suitable drift. Machine the seat.

Note! Where necessary, standard size seats can be replaced
by inserts with a larger outer diameter. See technical data,
point cylinder head.

23--- 10

A
Inlet
35 ---20
Exhaust 45 ---20

110,1

B
35+20
45+20

C
0,70,05 mm (max. 2,20 mm)
0,60,05 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 less than 1,5 mm after it has
been ground, or if the valve stem is bent, the valve should be
discarded.

48,500...48,525

3. If necessary, grind the end of the valve stem.

23--- 9

The inlet valve seat machined direct on the cylinder head, can
be provided with a separate valve seat ring, order no 8366
47936. Machine the seat insert location on the cylinder head
(see figure above). Fit the insert like a seat of the exhaust
valve.
More powerful engine specs are equipped with separate inlet
valve seats. Use in these engines when repairing seat ring no.
8368 55347. See technical data, point cylinder head.

4. Lap the valves with lapping paste and check the contact
surface with marking paint.
5. Clean the cylinder head and valves of any remaining lapping paste.

H. Fitting valves
1. Check the valve springs for straightness, length and tension using a spring tester. Compare with specifications.
2. Lubricate the valve stems and fit the valves in the correct
order in the cylinder.
3. Fit the springs, spring guides and valve keepers with the aid
of a lever for compressing valve springs, 9101 66200.
4. Tap the end of the valve stems lightly after fitting the valve
in order to ensure that they are secure.

Cylinder Head

3---4

I. Fitting cylinder head

1. Measure the length of the cylinder head bolts. Compare
with dimensions shown in figure below. Change too long
bolts.

14

16

12

max. 142

10

15

17

11

13

320, 620, 634

max. 188,5
21

22

19

20

3. Check that the sealing surfaces are clean and fit the cylinder
head gasket(s) and the cylinder head(s). Ensure that on the
six cylinder engines both cylinder heads are parallel by
fastening lightly the exhaust manifold before tightening the
cylinder head bolts (the exhaust manifold can damage, if the
heads are not parallel). Clean and lubricate and fit the bolts.

6
2

18

11
7

14

17
16

23--- 11

2. Screw the cylinder head stud bolts in to the cylinder block

to a torque of 30 Nm. Fit the valve tappets if removed.

12
10

23--- 12

15

13

420

23--- 13

4. Pictures above show the correct tightening order of the cylinder head bolts. The order has also been marked on the cylinder heads.
5. Tighten the cylinder head bolts progressively as follows:
1. First tightening to 80 Nm
2. Tightening of 90
3. Tightening again of 90.
6. Adjust the valve clearances (see instruction 4 C).
7. Run the engine with a light load to the normal running temperature (~ 75C).
8. Tighten the bolts 60 and adjust the valve clearances.
Note! After this the cylinder head does not need retightening.

Tighten the exhaust manifold bolts/nuts to 50 Nm. DO NOT OVERTIGHT!

50 Nm

23--- 131

Valve Mechanism

4. VALVE MECHANISM

4---1

60

A. Reconditioning valve mechanism

1. Check the valve tappets, especially the contact surface
against the camshaft. Worn or damaged tappets should be
discarded.

24--- 4

5. Fit the plug to the other end of the rocker arm shaft. Lubricate the shaft and fit various parts in a correct order. 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 figure above). Fit the other end plug.
NOTE! ENGINES FROM 96 WEEK 34
24--- 1

2. Check the straightness of the pushrods by rolling them on

a surface table. Check also the spherical surfaces at the ends.

From the above mentioned date a new valve mechanism,

push rods and rocker cover fastening taken in use.
The modification effects mainly the under mentioned parts:

3. Dismantle and clean the rocker arm mechanism. Check the

shaft for wear and that the oilways are clean.

24--- 2

19,990...20,010
24--- 5

4. Check that the rocker arm bushings are not worn. Ensure
that the oil hole is positioned correctly when pressing in new
bushings. After pressing in the bushings they should be reamed to 19,990...20,010 mm. Where necessary grind the
rocker arm valve contact surface to the correct shape. Do not
grind more than necessary as the hardened layer is thin.

--- Valve mechanism shaft diameter grows from 20 23 mm.

The plugs in both ends are replaced by threaded plugs.
--- The rocker arm is without bushing. The adjusting screw is
modified from M8 M10x1.
--- The push rod top end ball cup is growing from R4 R5.
--- The bracket structure and material is modified.
--- The rocker cover studs are shorter and the cover is tightened with hexagon screws.

24--- 3

As spare part the separate parts are not exhangeable. The

whole valve mechanism can be replaced with the new one together with the new push rods. The fastening parts do not
have to be modified.

Valve Mechanism
B. Changing camshaft/camshaft gear
1. Remove the inlet pipe between the turbocharger and the
induction manifold. Remove the valve cover and the breather
pipe. Remove the rocker arm mechanism.

4---2

Modification of the cam shaft

From engine no L 13188 all 620/ 634--- engines are equipped
with a cam shaft where the front end bearing location has no
oil groove ( the bearing location is so called barrel shape).

2. Remove the radiator, cooling fan, alternator and the v ---belt.

3. Remove the crankshaft nut. Remove the V ---belt pulley including the hub (on 620---engines the belt pulley must be removed first).

30

4. Remove the timing gear casing cover (engine front cover).

21--- 3/1

Note! The new cam shaft is not fitting together with any previous bushing. The new bushing is recognised from the position of the oil drilling which is not at the same place as the oil
drilling of the cylinder block, 30 angle upwards from the horizontal level.

24--- 6

5. Connect the pushrods in pairs, using o---rings or elastic

bands to prevent them from falling through.
Note! Do not connect the pushrods too tightly as this might
cause them to bend or snap.
6. Crank the engine until the aligning marks on the idler gear
and camshaft gear are facing each other. Extract the camshaft.
7. Separate the camshaft from the gear wheel using a press
or suitable drift.
8. Clean the parts which are to be refitted.
9. Fit the key in its groove. Heat the camshaft gear to 200C
in an oven and fit it on the shaft.
10. Lubricate bearing surfaces and lobes and insert the shaft
in the cylinder block. Ensure that the aligning marks on the
gears agree.
11. Fit the timing gear casing cover and the crankshaft V ---belt
pulley and hub.
12. Free the pushrods and fit the rocker arm mechanism. Adjust the valves. Fit the valve cover and the breather pipe and
the inlet pipe between the turbocharger and the induction
manifold.
13. Fit the alternator. Fit the fan and the fan belt. Fit the radiator.

Valve Mechanism
C. Adjusting valves

0,35

24--- 7

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 cylinders are adjusted in the same sequence as the order of injection.
--- slacken the lock nut of the adjusting screw
--- measure clearance with a feeler gauge. The clearance is
correct when a 0,35 mm feeler gauge is slightly tight---fitted
between the rocker arm and the valve stem end. Adjust clearance by rotating the adjusting screw.
--- tighten the locking nut and check the clearance

320, 620, 634

420

24--- 8

I = Inlet
P = Exhaust
320 ---engines
Check the valve clearances in the injection order of the engine. Injection order is 1---2---3.
--- Check valves in the 1st cylinder, when the exhaust valve of
no. 3 cylinder is completely open (valve no. 6).
--- Check valves in the 2nd cylinder, when the exhaust valve
of no. 1 cylinder is completely open (valve no. 2).
--- Check valves in the 3rd cylinder, when the exhaust valve of
no. 2 cylinder is completely open (valve no. 4).

4---3

420 ---engines
--- Rotate the crankshaft in the running direction until the
valves in the 4th cylinder are rocking (exhaust closes, inlet
opens). Check the valve clearance of the 1st cylinder.
--- Rotate the crankshaft by 1/2 of a turn in the running direction so that valves in the 3rd cylinder are rocking. Check
valves in the 2nd cylinder.
--- Continue according to the order of injection:
Injection order

1 2 4 3

Valves rock in cyl. no.

4 3 1 2

620/634 ---engines
--- Rotate the crankshaft in the running direction until the valves in the 6th cylinder are rocking (exhaust closes, inlet
opens). Check the valve clearance of the 1st cylinder.
--- Rotate the crankshaft by 1/3 of a turn in the running direction so that valves in the 2nd cylinder are rocking. Check valves
in the 5th cylinder.
---Continue according to the order of injection:
Injection order

1 5 3 6 2 4

Valves rock in cyl. no.

6 2 4 1 5 3

Crankshaft

5---1

5. CRANKSHAFT
A. Removing crankshaft
1. Remove the oil sump.
2. Disconnect the balancing unit lubricating oil pipe from the
cylinder block and unscrew the balancing unit fixing bolts. Remove the balancing unit and the lubricating oil pipe (only
420 ---engines).
3. Unscrew the lubricating oil pump pressure pipe fixing
screws from the cylinder block. Remove the oil pump and the
suction and pressure pipes.

25--- 2

4. Remove the flywheel and the flywheel housing.

5. Detach the belt pulley/hub from the crankshaft front end
(see instr. timing gears).
6. Remove the connecting rod bearing caps and push the
connecting rods out of the way of the crankshaft.
7. Remove the main bearing caps and lift out the crankshaft.

4. If the bearing clearance exceeds 0,18 mm for main bearings or 0,14 mm for connecting rod big ---end bearings with
new bearing shells, the bearing journals on the crankshaft
should be ground. Refer to the specifications for the relevant
correct undersize and the corresponding bearings, see
technical data, point crankshaft. When grinding note that
the journal edges must remain round.
Note! If needed, also the main bearing can be fitted with outer
diameter 1,0 mm oversize and inner diameter 0,5 mm undersize. Ordernumber is 8361 40950 (includes halfs 55593 and
55600). The main bearing housing is machined to
92,000...92,025 and crankshaft to 84,485...84,520.

B. Checking crankshaft
1. Clean the crankshaft. Do not forget the oilways.

C. Changing crankshaft gears

9052 48800

25--- 1

2. Measure the journal wear in several points. Out---of ---round,

taper or other wear must not exceed 0,03 mm.
3. Refit the bearing caps with new bearing shells and tighten
them to the correct torque. Measure 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 clearance. Measure in several points in case the worn bearing
housing is not round.

25--- 3

1. Apply puller for the crankshaft gears and pull off both gears.
2. Clean the seat on the crankshaft with, for example, a wire
brush.
3. Heat the new gears to 200 C. Tap them onto the shaft with
a suitable sleeve or soft drift. Note the position of the key and
ensure that the aligning marks on the front gear are visible.
Leave it to cool.

Crankshaft
D. Changing crankshaft gear rim
(420---engines only)
20

5---2

2. Assembly the bearing with oilholes/groove (A) to the cylinder block and the bearing with no hole (B) to the bearing cap.
Ensure that the bearing shell clamping claws fit into their
notches and that the shells to be fitted in the cylinder block
have a hole coinciding with the oil port.
3. Lubricate the bearing surfaces and fit the crankshaft. Fit the
crankshaft thrust bearings with the lubricating grooves facing
the crankshaft.

200 Nm
25--- 4

1. Mark the position of the gear rim on the shaft.

2. Heat the gear rim with a welding torch and drive it off using
a suitable drift.
3. Heat the new gear rim to max. 250C. Fit the gear rim with
the chamfer facing the crankshaft flange, and with the teeth
according to markings or according to figure above. Tap the
gear rim down and leave it to cool.
Note! The figure above shows a rear view of the crankshaft
and no 2 cylinder big end bearing journal.

25--- 6

4. Fit the main bearing caps according to their numbering

(bearing lock in the block and in the cap are on the same side),
the rear with thrust bearings provided with guide lugs. Lubricate the bolts and tighten them to 200 Nm.

0,10...0,35 mm

E. Fitting crankshaft
1. Clean the oilways, bearing shells and bearing locations.
Check that the crankshaft is clean.

B
25--- 7

5. Check that the crankshaft can rotate without binding. Check

the end float using a dial gauge. The correct end float is
0,10...0,35 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

25--- 5

Crankshaft

5---3

Note! 320---engines. Tightening torque of screws of crankshaft counterweight is 160 Nm. Apply locking fluid Loctite
2701 on the screw threads.

3. Fix the new vibration damper/pulley on the crankshaft. Tap

the timing indicator in its place and tighten the fixing screws
to a torque of 30 Nm.

F. Crankshaft hub piece

Note! Vibration dampers (pulleys) delivered as spare parts do

not have injection timing mark. Make the marking on the new
damper in connection with installation.
4. Rotate the crankshaft until the piston of the 1st cylinder reaches its top dead centre. Drop cyl. no 1 inlet valve down
against the piston head. Set the dial gauge on top of the valve
stem end and zero it at the piston top dead centre. Then rotate
the crankshaft opposite to running direction until dial gauge
shows about 15 mm below TDC. After that rotate the crankshaft slowly to running direction until the dial gauge shows the
figure corresponding injection timing (see table below).
5. Mark the injection timing on the tip of indicator with an electric pen (do not tap).

25--- 8

When fitting the hub piece to the crankshaft front end note the
correct position of the hub. (Engines with the timing mark on
the crankshaft pulley/vibration damper.) The hub piece has an
installation mark --- on two teeth and the corresponding installation mark of the crankshaft is on one tooth.

G. Changing crankshaft pulley/vibration damper

25--- 9

1. Loosen the alternator fixing screws and remove the v ---belt.

2. Open the bolts of the pulley/vibration damper and remove
the parts. The pulley/vibration damper is positioned to the
crankshaft hub with a timing indicator (engines with timing
mark on the pulley/vibration damper).

Piston distance from top dead centre vs. crank angle

Grad
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

320, 420, 620

mm

634
mm

0,012
0,047
0,106
0,188
0,294
0,423
0,576
0,752
0,951
1,173
1,418
1,686
1,976
2,289
2,625
2,983
3,363
3,765
4,188
4,633
5,100
5,587
6,095
6,624
7,173
7,742
8,331
8,939
9,567
10,213

0,013
0,054
0,121
0,216
0,337
0,485
0,660
0,861
1,089
1,344
1,624
1,931
2,264
2,623
3,007
3,417
3,852
4,312
4,797
5,307
5,841
6,399
6,980
7,585
8,214
8,865
9,539
10,235
10,952
11,692

Crankshaft
H. Checking element of the rubber
damper (620/420)

5---4

I. Viscose type vibration damper

2

1,5

3
4

25--- 12

30 Nm

25--- 10

1. Check the alignment marks (A) on both sides of the rubber

element. If the difference is more than 1,5 mm, change the
damper for a new one.

1. Housing
2. Damper mass
3. Liquid cavity
4. Bushing

In the 634---engines and some 620---engine versions there is

a vibration damper of so---called viscose type. Inside the
damper there is a housing filled with stiff silicone oil in where
the damping substance is situated with very small tolerances.
Note! Even a small dent makes the vibration damper inoperative. Do not remove it by turning forcibly and be careful not
to damage it when it is loose. If you detect a dent on the outer
surface, do not install the damper back in the engine.
Note! Mark the injection timing on the vibration damper with
an electric pen (do not tap).

25--- 11

2. Check also the condition of the rubber element. If rubber

pieces have been loosened from the element, rubber has
been pressed to the depth of more than 3,5 mm or the outer
circumference is slack or it moves in the direction of the shaft,
change the damper.
Note! Vibration damper should be replaced every 4000
running hours!

Connecting Rods and Pistons

6---1

6. CONNECTING RODS AND

PISTONS
A. Removing pistons together with
connecting rods

40,025...
40,040

1. Remove the oil sump and the oil inlet and pressure pipes.
2. Remove the cylinder head.
3. Scrape off the possible soot in the cylinder liner. If the turning edge is clearly marked, smooth it down carefully with a
scraper.
4. Remove the big ---end bearing caps and bearing shells.
Place the shells in order if they are to be re ---used.
5. Push up the piston and connecting rod with the shaft of a
hammer or similar wooden tool.
6. Remove the piston pin snap rings. Push out the pin.
Note! If the piston pin does not move under thumb pressure
the piston should be heated to 100C.

B. Changing connecting rod bearings

26--- 2

4. Press the new bush in its place. Ensure that the oil hole in
the bush coincides with the respective hole in the connecting
rod. After fitting drill 5 mm oil hole and ream the bush to attain its correct diameter.
Note! The connecting rod can, if needed, be fitted with a 0,5
mm oversize bushing (8353 28326). See technical data, point
connecting rod.
Big end bearing
1. Fit the bearing shells together and tighten the screws.

Piston pin bushing

2. Measure the I.D. using a cylinder gauge which has been

zeroed to the diameter of the respective bearing journal. If the
clearance exceeds 0,14 mm with new bearing shells, the big
end journals require grinding. Refer to the specifications for
the correct undersize and the corresponding bearing. Ensure
that the radii at the end of the bearing journals is not altered
when grinding.

1. Clean the connecting rod and bearing shells.

C. Checking connecting rod

The connecting rod is checked in a special fixture, intended
for the purpose (e.g. Carl Larsson). See technical data, point
connecting rod.
Note! If the connecting rod is damaged so that it has to be
changed, please note the following:

26--- 1/1

2. Measure the I.D. of the piston pin bushing using a cylinder

gauge.
3. If the piston pin bushing is worn, it should be driven out
using a suitable drift.

--- The earlier used connecting rod is replaced in production

with a new type from engine number L 11212. In the new connecting rod the big end is split by the breaking technique.
--- Single connecting rods are not interchangeable. As spare
part the new connecting rod replaces the earlier only by
changing the whole set.

Connecting Rods and Pistons

Earlier used connecting rod

6---2

New connecting rod from engine number L 11212

H
X
max. 86,50

40 Nm + 90

Torx E18

40 Nm + 90
Measure the length of the connecting rod screws. The length
should be max 86,50 mm. If the screw is longer, change it with
a new one. It is recommended that the screws are always
changed when they are unscrewed.
The connecting rods are divided into weight classes with intervals of 20 g. The weight class (a letter) is stamped on the side
face of the connecting rod. All the connecting rods in one engine should be of the same weight class, that is to say the
greatest permissible weight difference is 20 g.
The letters show the weight classes as follows:
Letter

Part no.

Weight

X
A
B
C
D

8366 47460
8366 52104
8366 52105
8366 52106
8366 52107

2150---2169 g
2170---2189 g
2190---2209 g
2210---2229 g
2230---2249 g

E
H
I
J
K

8366 52108
8366 52109
8366 52110
8366 52111
8366 52112

2250---2269 g
2270---2289 g
2290---2309 g
2310---2329 g
2330---2349 g

L
M
N
O
P

8366 52113
8366 52114
8366 52115
8366 52116
8366 52117

2350---2369 g
2370---2389 g
2390---2409 g
2410---2429 g
2430---2449 g

R
S
T
U

8366 52118
8366 52119
8366 52120
8366 52121

2450---2469 g
2470---2489 g
2490---2509 g
2510---2529 g

Note! Always change the screws when opened.

The connecting rods are divided into weight classes with intervals of 20 g. The weight class (a letter) is stamped on the side
face of the connecting rod. All the connecting rods in one engine should be of the same weight class, that is to say the
greatest permissible weight difference is 20 g.
The letters show the weight classes as follows:
Letter
F
V
X
Y
W
Z
G

Part no.

Weight

8366 66430
8366 66431
8366 66432
8366 66433
8366 66434
8366 66435
8366 66436

1935---1954 g
1955---1974 g
1975---1994 g
1995---2014 g
2015---2034 g
2035---2054 g
2055---2074 g

Connecting Rods and Pistons

D. Changing piston rings
1. Remove the piston rings with piston ring pliers 9052 46900.
Do not open the rings more than necessary. If the rings are to
be used again ensure that they are fitted in the same groove.

6---3

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 manufacturers designation, faces upwards.

26--- 9
26--- 11

2. Clean the piston ring grooves and measure the piston ring
clearance, which must not exceed 0,15 mm. Determine
whether too large a clearance is due to worn rings or a worn
groove. Change worn parts.

E. Checking pistons
Check the condition of the pistons and piston pins. Pay
special attention to possible cracks on the edge of the combustion chamber and on the upper edge of the piston pin
hole. Measure the diameter of the piston at the point shown
in the figure below. Renew a piston if needed.

634:

26--- 10

3. Measure the piston 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 1,5 mm on 2. piston
ring.

320, 420,
620:

26--- 12

Connecting Rods and Pistons

F. Fitting piston pin
1. Place the connecting rod inside the piston and push the piston pin into place.
Earlier used connecting rod

6---4

G. Fitting piston together with connecting rod.

1. Check that the bearing locations are clean and place the
bearing shells in the connecting 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.

9020 01100
26--- 13

The combustion chamber and the weight class letter should

be on opposite sides.
New connecting rod

26--- 14

3. Use a piston ring strap or preferably a fitting tool. 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 ---end bearing journal and bearing shells,
and push the piston down. Fit the bearing cap so that the
notches for the guide lugs are in the same side. Tighten the
connecting rod screws to 40 Nm+90.
5. Check that the connecting rod has sufficient end float on the
big ---end bearing journal.

26--- 13/1

The combustion chamber and the weight class letter should

be on same side.
2. Fit the piston pin circlips. Ensure the the circlips are pressed
correctly into the grooves. The circlip ends must point upwards.

Counterbalance

7---1

7. COUNTERBALANCE (420)
A. Removing and disassembling
counterbalance unit
1. Remove the oil sump
2. Disconnect the lubricating oil pipe of the counterbalance
unit.
3. Remove the counterbalance unit. Take care of any shims.
4. Loosen the locking screws and press out the shafts in the
direction of the locking screws. Remove the counterweights
and thrust washers.

0,1...0,5 mm

5. Clean all parts.

B. Reconditioning counterbalance
unit
Check the shafts, gear wheels and bushings for wear and
damage.
1. If one of the gear wheels is damaged, change both counter
weights as a complete unit. The gear wheels are not available
separately as a spare part.

27--- 2

4. Check that the tooth backlash is 0,05...0,25 mm and that

the end float is 0,1...0,5 mm

C. Fitting counterbalance unit

1. Fit the tension pins to the cylinder block.

2. Remove, if necessary, the old bearing bushings with a suitable drift. Before removing them, mark the position of the
bushing oil groove on the counter weigh. Press in new bushings in the correct position. After fitting the bushings should
be reamed to a correct dimension, see Specifications.

27--- 3

2. Turn the crankshaft and weights so that the markings agree,

and lift the unit into place.

27--- 1

1. Synchronisation marking (notch)

2. Marking against crankshaft (punch mark)
3. Place the weights in the body, observing the notch markings. The gear wheel with the punch mark runs against the
crankshaft and should therefore be placed highest. Insert the
shafts, remembering the thrust bearings. Apply thread lock
fluid Loctite 270 to the locking screws, and lock the shafts.

3. Tighten the bolts to 60 Nm. Check that the tooth backlash

between the crankshaft and counterweight is 0,1...0,3 mm.
The backlash can be increased by placing shims 0,2 mm thick
(order no 8361 19920) between the cylinder block and balancer unit body. One shim (0,2 mm) changes tooth backlash
about 0,07 mm.
4. Fit the lubricating oil pipe, using new seals.
5. Fit the oil sump.

Flywheel

8. FLYWHEEL

8---1

Note! E ---engines flywheel delivered as spare parts do not

have injection register mark. Make the marking on the new
flywheel in connection with installation.

A. Changing starter ring gear on flywheel

If the ring gear is worn, change it with a new one. The ring
gear cannot be turned around because its teeth are chamfered and hardened on the starter motor side.
1. Remove the old starter ring by tapping it at various points
with a drift. Clean the flywheel contact face with a steel---wire
brush.

--- Rotate the crankshaft until the piston of the 1st cylinder reaches its top dead centre. Drop cyl. no 1 inlet valve down
against the piston head. Set the dial gauge on top of the valve
stem end and zero it at the piston top dead centre. After that
rotate the crankshaft slowly to running direction until the dial
gauge shows 4,633 mm ATDC (420, 620) or 5,307 mm ATDC
(634).
--- Bore the injection register mark hole by a drill (see picture
below) to the flywheel.

28--- 1

2. Warm the ring gear to the temperature of 150...200C. Fit

the ring gear with the inner diameter chamfering turned
against the flywheel and the teeth chamfering against the
starter motor.
3. Allow the ring gear to cool freely without using any coolant.

B. Fitting flywheel
Note! In E ---engines the injection register mark is marked on
the flywheel. The flywheel has been positioned to the crankshaft with aid of quide sleeve.
1. Clean the contact surfaces on the crankshaft rear flange
and on the flywheel.
2. Fasten the flywheel to the crankshaft rear end. As a guide
pins can be used studs (M12, 2 pcs) which are screwed in to
the flywheel fixing bolt holes. The position of the flywheel is
free in engines where the injection timing is marked on the
crankshaft front end. In some engine versions one of the retaining screws have been replaced by a guide pin to determine the crankshaft position.
3. Tighten the flywheel retaining screws evenly to a torque of
140 Nm (10.9) / 150 Nm (12.9).

Timing Gear Assembly

9---1

9. TIMING GEAR ASSEMBLY

7. Unscrew the idler gear bolts (17 and 22 mm). Remove the
flange, gear wheel and bearing journal.

A. Removing timing gear casing

8. Extract the camshaft.

As the timing gear casing bottom face forms a part of the mating face for the oil sump gasket, the casing cannot be removed without first removing the oil sump.
1. Remove the oil sump.
2. Remove the radiator, fan, alternator, belt tensioning and belt
(if not removed earlier). If the engine is equipped with a air
compressor or air conditioner, it has to be removed.

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 casing. Ensure that all sealing surfaces are not damaged.
10. Remove the crankshaft front sealing ring from the front
casing and clean all the parts that have been removed.

B. Reconditioning idler gear

If the idler gear bushing is changed, press in a new bushing
so that its rear edge is 0,1...0,25 mm inside the gear wheel
rear edge (see picture on next page).

1
2

9101 65700

29--- 1

3. Loosen the crankshaft nut (special tool 9101 65700 for 320,
420, 620---engines and tool 9024 55800 for 634 engines) and
remove the belt pulley/hub.
Note! On 620---engines the belt pulley must be removed before unscrewing the nut. If the 620---engine is equipped with
a viscose damper, the front end nut is opened with tool 9024
55800.
4. Remove the drive unit and hydraulic pump (if installed).
5. Remove the timing gear casing cover and the oil deflector
ring at the front end of the crankshaft.
6. Remove the injection pump.
Note! If the timing gear casing is not to be changed, the injection pump can remain in place. In which case disconnect all
leads and pipes from the pump.

29--- 2

1. Chuck of lathe
2. Roller =5 mm

Machine the idler gear bushing inner diameter to a correct dimension after fitting. Centre the idler gear according to figure
above so that tooth backlash is kept the same.

Timing Gear Assembly

9---2

29--- 4

4. Fit the idler gear with shaft stud and ensure that the markings are in the correct position. Fit the washer and tighten the
bolts to the correct torque.

29--- 3

C. Fitting timing gear casing

The position of the timing gear casing and cover is determined by two tension pins. Therefore centring should not be
undertaken in connection with fitting. However, the tooth
backlash between the different gears should be checked.
Casing and covers that are delivered as spare parts also have
holes for the tension pins already machined.
1. Fit the casing with a new gasket against the cylinder block.
Drive in the tension pins with drift 9025 98700. Tighten bolts
and nuts.
2. Fit the injection pump together with gear wheel (if removed).
3. Lubricate the camshaft bearings and insert the shaft in the
cylinder block. Release the pushrods and tappets if they have
been suspended.

29--- 5

5. Check the tooth backlash which should be 0,05...0,25 mm.

Timing Gear Assembly

9---3

9025 98700
9025 98800

29--- 6

6. Fit the oil deflector ring on the crankshaft and fit the timing
gear casing cover using a new gasket. Drive in the tension
pins with drifts 9025 98700 and 9025 98800 respectively (the
tubular pin round the screw stud). Tighten bolts and nuts.

9025 98900

29--- 8

8. Fit the dust shield on the crankshaft V ---belt pulley hub, if it

has been removed. Use drift 9025 98900.

9030 15200

29--- 7

7. Fit the protective plate into the seal location and fit the
crankshaft front seal with special tool 9030 15200.

600 Nm (320, 420)

1000 Nm (620, 634)

29--- 9

9. Lubricate both the seal and sealing surfaces and fit the
crankshaft V ---belt pulley with hub.
10. Lubricate the crankshaft nut threads. Tighten the nut to
600 Nm on 320--- and 420---engines and 1000 Nm on 620 and
634 engines.
11. Fit the other detached parts.

Timing Gear Assembly

9---4

D. Idler gear with bevelled ball bearings

1

8
1. Camshaft gear
2. Idler gear
3. Injection pump gear
4. Hydraulic pump gear
5. Crankshaft gears
6. Oil pump gear
7. Idler gear of compressor
8. Compressor gear

7
5

29--- 10

In some 620/634---engines versions bevelled ball bearings

are need in the idler gear. The two---cylinder compressor,
fitted to the gear housing, is run trough a separate rear.

30 Nm

22 Nm
29--- 12

180 Nm

29--- 11

2. If the compressor gear shaft has been removed, apply on

its outer face Loctite 601 and hit the shaft in its position so that
the shaft and gear housing back surfaces are at the same
level. Fit the bearing and the gear so that the groove of the
bearing inside ring comes outwards. Remember the lock
rings! Fit the retaining ring and tighten the screws to 30 Nm.

1. Fit the idler gear bearings, as the picture shows, pressing

from the outer ring. Fit the holding ring and tight the bolts,
lightly oiled, to 22 Nm. Press the shaft to its position supporting the bearing from the inner ring. The idler gear screw tightness is 180 Nm.

29--- 13

3. Note when assembling the camshaft, the timing mark that

differs from the other engines.

Timing Gear Assembly

E. Power take---off
In the 20/34---series engines is used a transmission that can
be equipped with a P.T.O. run from the camshaft gear. The
P.T.O. can run e.g. a hydraulic pump.

29--- 14

Note when assembling the P.T.O. the front bearing seal position.
Use molybdenite ---sulphide (MoS2) ball bearing grease
(NLGI 2) for the grooves of the hydraulic pump shaft and the
coupling sleeve.
Note! Some P.T.O. are equipped with on outer lubricating
possibility (pipe). In this case the front bearing is not sealed
(like in picture). This P.T.O. is known from the M6x1 thread in
the cover.

9---5

Lubrication System

10---1

10. LUBRICATION SYSTEM

A. Reconditioning of oil relief valve
for lubricating oil pressure

Loctite 638

If the engine lubricating oil pressure is insufficient or if it varies,

the relief valve should be checked after first checking the oil
level.

210--- 1/1

B. Removing and dismantling lubricating oil pump

1. Drain the engine oil and remove the oil sump.
210--- 1

1. Remove the cover over the valve and spring. Take care of
the washer between the cover and spring. Remove the valve
insert together with the valve cone and ensure that the o---ring
is also removed.
2. Clean the parts and check that the valve cone slides freely
in the insert and that the sealing surface are undamaged. Minor damage can be adjusted, but in general, damaged parts
should be changed. Scrape off any remains of the gasket.
3. Assemble the valve with a new o---ring and insert it in the
cylinder block. Place the washer and spring in the cover and
fit it with a new gasket.

2. Remove the oil pump suction and pressure pipe.

3. Remove the oil pump together with any shims between the
pump and the cylinder block.
4. Remove the pump cover and the gasket. Remove the gear
on the dead axle.
5. Clamp the pump gear across the teeth in a vice fitted with
soft jaws, and loosen the drive gear nut. Knock the gear wheel
off by hitting the end of the shaft with a soft hammer. Pull out
the drive shaft---gear wheel
6. Clean the parts and check for wear and other damage.
Compare with the specifications. Change damaged parts and
all seals.

210--- 2

4. Note that the relief valve cover is not symmetrical. The

greater distance between the spring housing and bolt should
be turned downwards.
Note!
From engine no. J 7595 (engines without oil cooled piston)
From engine no. J 14016 (engines with oil cooled piston)
The engines are equipped with 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.

60 Nm

210--- 3

7. On 620/634---engines the bearing points are provided with

separate bearing bushings. If You change the bushings, machine them to dimension of 18,000...18,018 after fitting.

Lubrication System

10---2

Note!
320---engines from engine number C 1474
420---engines from engine number C 1328
620---engines from engine number C 1133
The connection between the gear and shaft in the lubrication
oil pump has been modified to a conical connection without
key.
The new gear and shaft/gear combination can be used as a
pair in pumps of earlier type.

2
1

210--- 5

3. Fasten the oil pump in a vice and check the end float between gear and pump housing. The clearance which should
be 0,03...0,11 mm, is adjusted by the number of gaskets between the cover and body.

210--- 4

1. Gear
2. Shaft/gear
Note!
620/634 engines from engine number J 7891.
As a part of the standardization process all 6---cyl. engines are
now fitted with the same oil pump. The pump 8368 52607 in
620 engines and 8363 38187 in 634 engines has been replaced with 8368 55300.
The new pump can be used also in older 6---cyl. engines,
when suction and pressure pipes are replaced as well (location of pipe connection is different in respect to crankshaft
center line).

C. Assembling and fitting lubricating

oil pump
1. Fit the gear wheels in the pump body. Fit the cover using
a new gasket. Partly tighten the bolts. Rotate the pump shaft
and tap the side of the cover lightly until the position is reached
where the shaft rotates most freely. Tighten the bolts and
check that the shaft still rotates freely.
2. Fit the key and drive gear onto the shaft (tapered joint without key on the later pumps). Apply Loctite 242 onto the nut
threads and tighten the nut to 60 Nm. Remember the washer
under the nut.

210--- 6

4. Fit the pump and check the tooth backlash against the
crankshaft gear. The clearance, which should be 0,05...0,25
mm, is adjusted with 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 clearance affects the tooth backlash.
5. Connect suction and pressure pipes together with new
seals. Fit the oil sump and fill in the lubrication oil.

Lubrication System

10---3

D. Fitting oil sump gasket

F. Piston cooling nozzles (620/634)

Fit the oil sump gasket with the silicone stripes against the cylinder block (self carrying and casted oil sumps).

The cooling nozzles can be removed after removing the oil

sump. The nozzles have a ball valve with an opening pressure
of 30,25 bar.

210--- 7

E. Lubricating oil cooler

Some engines are equipped with a oil cooler, positioned in
between the oil filter and the cylinder block.
1. The engine coolant should be drained before removing the
lubricating oil cooler.

60 Nm

210--- 9

1. Change the valve if necessary. Detach the valve from the

engine and remove the nozzle pipe. Fit a new valve.

90

210--- 10

210--- 8

2. Fit new sealing rings. Fit the cooler with draining plug turned downwards. Connect coolant pipes in the correct way.
3. Apply locking fluid to the nipple (the thread which attaches
to the filter head) and tighten it to a torque of 60 Nm.

2. Fit the nozzle pipe at the angle of 90 to the centre line of

the crankshaft according to the above picture. Tighten the valve to 30 Nm. Ensure that the pipe does not touch the pistons
or connecting rods when the engine is running.

Lubrication System

10---4

G. Lubricating oil quality requirements

--- Naturally aspirated and turbocharged engines
--- Low emission (E) engines

API CF ---4, CG ---4, CH---4

API CG ---4, CH---4

ACEA E2/E3 ---96, E4 ---98, E5 ---99

ACEA E3 ---96, E4 ---98, E5 ---99

TEMPERATURE C

SAE---GRADE

---40

---30

---20

---10

+10

+20

+30

+40

5W---30
5W---40
10W---30
10W---40
15W---40
20W---20
20W---40
30
210--- 11

Cooling System

11---1

11. COOLING SYSTEM

A. Thermostat

211--- 3

211--- 1

The thermostat is of a two---way type. Its opening temperature

is 79C. In winter a thermostat can be used with an opening
temperature of 83C.
Check the function of the thermostat as follows:
--- Lower the thermostat into a vessel of boiling water so that
the thermostat does not touch the sides or bottom.
--- Opening must begin under 20 seconds.
--- The thermostat must be fully open under 50 seconds.
Stroke, see specifications point thermostat.

The rubber seal ring between the coolant pump and the thermostat housing has been modified to two o---ring seals.
At the same time also the by ---pass pipe is modified. The new
parts can, during a repair, be installed instead of the earlier
used.

B. Reconditioning coolant pump

(320, 420)
1. Drain the engine coolant. Disconnect the water hoses from
the thermostat housing and from the coolant pump. Remove
the thermostat housing and the by ---pass pipe.
2. Slacken the alternator fixing bolts. Remove the fan and the
pump belt pulley. Remove the v ---belt.
3. Detach the coolant pump. Remove the pump rear plate and
clean the sealing surfaces.

9052 48900

211--- 2

Some 620/634---engines have two separate thermostats.

These are separated from the type of the single thermostat
and they are not interchangeable. To these engine there are
no separate winter thermostats.
Note! Modification of the by ---pass pipe.
320/420---engines from engine number D 3056
620---engines from engine number D 3532

211--- 4

4. Remove the fan hub using puller 9052 48900. Remove the
circlip from the pump body.

Cooling System

11---2

178,5 mm
174,5 mm
320 E 7536>
420 E 7055>

9104 27700

1,8...2,2 mm

320
420
211--- 5

5. Remove the impeller using puller 9104 27700. Press the

shaft out of the pump body in the direction of the fan. Use a
hydraulic press. Support the body so that the shaft bearing
unit has enough space for releasing.
6. Tap out the axial seal in the body using a suitable drift.
Clean all parts and inspect their condition. Replace damaged
parts with new ones.
Note! If the pump shaft has to be changed, use a reconditioning kit. This kit also contains all seals (see Parts Catalogue).
7. Press the shaft into its location in the body using special tool
9051 64900 and fit the circlip.

211--- 7

9. Press the impeller and the hub to the correct depth (see figure) and support the shaft at the other end. Ensure that the
shaft can rotate freely. Fit the rear plate using a new gasket.

C. Reconditioning coolant pump

(Separate ball bearings 320, 420, 620, 634)
1. Drain the coolant. Remove the thermostat housing, fan and
the v ---belt.
2. Remove the coolant pump. Detach the pump rear plate and
clean the sealing surfaces.
3. Unscrew the belt pulley fixing nut and remove the belt
pulley. Use puller 9052 48900 if needed.
9104 27700
9101 93200

9051 79300

9051 40200

8353 39425

8353 31202

211--- 6

8. Fit the axial seal. Use as a lubricating liquid coolant between the shaft and the seal. Two different seal types are
used. Both these seals are fitted with their own drift (see figure
above).

211--- 8

4. Remove the impeller on the shaft with puller 9104 27700

(320/420---engines) or 9101 93200 (620/634---engines).
5. Remove the circlip in the pump body. Press the shaft together with bearings in the direction of the fan. Use e.g. a hydraulic press. Support the pump body so that the bearings
have enough space for releasing.

Cooling System
6. Tap out axial and shaft seals using a drift. Clean the parts
and inspect their condition. Replace faulty or worn parts with
new ones.
Note! If the pump bearings have to be changed, use a reconditioning kit. This kit also contains all seals (see Parts Catalogue).
7. Drive in the new shaft seal in the housing using a suitable
drift. Put the bearings and the intermediate sleeve onto the
shaft. Grease bearings with heat---resistant ball bearing
grease. Fit the shaft and the bearings in such a way that the
pressing force is not transmitted by the bearing balls. Fit the
circlip for the bearing.

11---3

11. Fit the rear plate using new seals. Use in 620/634---engines guide pins (8,5 mm) in the holes shown with arrows in
the picture 211---10.
Note! Some 320/420---engines are equipped with a new type
of coolant pump, where the diameter of impeller has changed
87 > 97 mm. The reconditioning of this pump is done according to the instruction in part C.

8. Fit the axial seal, see instruction 11 B point 8.

9,0...9,3 mm

1,8...2,2 mm

80 Nm

120 Nm

211--- 9/1

Note specially the left hand thread of belt pulley fixing bolt and
the measuring point of position of impeller.
211--- 9

9. Press the impeller into position while, at the same time, supporting the shaft at the other end. The mounting depth of the
impeller is in 320/420---engines 1,8...2,2 mm and in
620/634---engines 0,8...1,2 mm (see figure above). Make
sure that the shaft can rotate freely.
10. Fit the belt pulley and tighten its attaching nut to a torque
of 120 Nm.

Loctite 572

211--- 9/2

If the rear plate is removed, fit the rear plate to the cylinder
block. Apply sealing compound to the thread of screw, see
picture above.

211--- 10

Cooling System
D. Coolant pumps with heavy---duty
bearings (620, 634)
Some versions of 620/634---engines have a heavy ---duty
bearings in the coolant pump. The reconditioning of this
pump is done according to the instruction in part C. Note
specially the position of the front bearing as assembling.

0,8...1,2 mm

120 Nm

211--- 11

E. Quality requirements of coolant

The coolant used must meet the standards ASTM D 3306 or
BS 6580:1992.
--- Mixing proportion should be 40---60 % of ethylene/propylene ---glycol based coolant and the rest water. The best ratio
is 50/50 %.
--- In warm climates the 30 % mixture ratio gives enough good
protection against corrosion.
--- Water used should be clean and soft water i.e. that it does
not include metals and their salts.
--- Check the coolant frost resistance every now and then.
Change the coolant every other year.
Note! Never use only water as coolant!

11---4

Inlet and Exhaust System

12. INLET AND EXHAUST SYSTEM

An engine that is equipped with a turbocharger is a great deal
more sensitive to disturbances and impurities in the inlet and
exhaust systems than a naturally aspirated engine. Therefore
special attention should be given to the whole inlet and exhaust system.

A. Checking air cleaner

The engine performance and length of service life depend to
a great extent on the state of the air cleaner. A defective air
cleaner allows impurities to pass through, which in time damage the turbocharger and the engine. A blocked air cleaner
lowers the engine output and also causes oil leakage through
the sealing ring on the turbocharger shaft.

12---1

C. Checking turbocharger
If a fault is suspected in the turbocharger it can be located in
the following way:
1. Visually inspect the turbine and compressor wheels. The
vanes must not show any signs of damage, deformation or
wear caused by foreign objects.
2. Investigate any oil leaks through the sealing rings on the
shaft in the turbine and compressor housing.
Note! At low idling there is always a certain amount of oil leakage on the compressor side. However, this should not cause
too much concern unless the oil consumption is too great.

Note! The safety filter inside the main filter should not be removed unnecessarily, for checking or cleaning. The safety
filter must not be cleaned, but should be changed once a year
or when necessary (see Operators Manual)

B. Checking inlet and exhaust pipes

Important! Leaks in the inlet or exhaust system markedly
lower the effect of the turbocharger. Because of the pressure,
even small leaks in the manifold or in the turbine inlet contact
flange quickly increase in size. For this reason all leaks must
be dealt with immediately.
1. Inspect the pipes and sealing surfaces between the air
cleaner and the turbocharger, as well as between the turbocharger and the intake manifold. If the intake manifold is dusty
on the inside, there is a leak in either the air cleaner or the inlet
pipes. Remedy the leak.

212--- 1

3. Check the turbine shaft running clearance. Place the stylus

of a dial gauge against the shaft and move the shaft sideways.
refer to the clearance given in the specifications on page
0 ---12.

2. Clean the intake manifold sealing surface. Check that the

sealing surface is flat using a straight ruler. If the surface is not
flat or it has scratches, machine or renew the intake manifold.
On 620/634---engines 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/bolts to 50 Nm and inspect for any damage (cracks, deformation, corrosion etc.). Check also the connection between the turbocharger and the exhaust manifold.
5. Remove the manifold if necessary. Clean the sealing surfaces and remove any carbon deposits. Check that the sealing surfaces are flat. If the fastening flanges are twisted or
there are scratches on the sealing surfaces, machine the
flanges or renew the exhaust manifold.
6. Ensure that no loose objects or impurities have entered the
exhaust pipe or the silencer. Any such loose objects or impurities can increase the back pressure for the exhaust gases
from the turbine wheel.

212--- 2

4. Check the shaft end float. Place the stylus of the dial gauge
against the end of the shaft and move the shaft axially. Refer
to the clearance given in the specifications on page 0 ---12.

Inlet and Exhaust System

12---2

If any defects or wear are confirmed, the turbocharger should

be reconditioned.
If the engine does not work correctly and the turbocharger is
not defective or too worn, the fault could be traced to one of
the following items:
--- Blocked air filter
--- Leakage in the inlet or exhaust systems. Leaking flange
seal
--- Defective or wrongly adjusted injection pump.
--- Wrongly adjusted throttle linkage
--- Defective or wrongly adjusted injectors
--- Low fuel pressure (e.g. blocked fuel filter)
--- Low compression, wrong valve clearance

Turbocharger Schwitzer S1A

1.
2.
3.
4.
5.
6.
7.

Compressor cover
Lock nut
Compressor wheel
Bearing housing
Journal bearings
Turbine housing
Shaft and turbine wheel

2
5

212--- 3

D. Fitting turbocharger
Locate the cause of the defects on the turbocharger. Remedy
the fault before fitting the new turbocharger.
In order for the turbocharger to work satisfactorily, it is important that the engine oil is in good condition. Likewise the oil
should be to the correct quality specification. The air filter and
oil filter should be serviced according to the handbook specification.
The setting of the 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
tighten down using a new gasket.

3. Connect the inlet pipe and the exhaust pipe on the turbo.
4. Pour clean engine oil into the bearing housing through the
inlet oilway. This is very important in order to ensure that the
turbocharger is lubricated at the time of starting.
5. Connect the pressure and return oil pipes. Use a new seal.
Check that there are no tensions in the pipes when tightening.
6. Before starting, pull out the stop control and crank the engine over with the starter motor so that the oil pressure rises.
Start the engine and check that there are no leaks.

Fuel System

13---1

13. FUEL SYSTEM

IN---LINE FUEL INJECTION PUMP
Note! This manual gives only general instructions for repair
and service measures related to the fuel system. This applies
particularly to the injection pump which can be repaired only
by a specially trained person who has the necessary special
tools and gauges. All service and repair work related to the
fuel system requires special care and cleanliness!

TECHNICAL DATA
Injection pump Bosch-- A/Bosch-- P
Type (pump/governor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection order:
--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 620, 634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of pump piston:
--- Bosch ---A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- Bosch ---P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke:
--- Bosch ---A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- Bosch ---P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch PES_A/RSV (PES6P/RSV)

1---2---3
1---2---4---3
1---5---3---6---2---4
clockwise
9,5 mm
12 mm
8 mm
11 mm
see injection pump adjusting values

Oil fillings 1):

--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 l
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 l
--- 620/634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6 l
1)

When fitting fuel injection pump.

Fuel feed pump

Type:
--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 420, 620, 634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel feed pressure (overflow valve opening pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure from fuel feed pump (without overflow valve) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch FP/KSG 24 AD 207

Bosch FP/KEG 24 AD 504
piston pump, separate hand pump
0,7---1,2 bar (70---120 kPa)
2,7 bar (270 kPa)

Injectors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 14---10
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495

Tightening torques
Injection pump gear nut:
--- Bosch ---A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- Bosch ---P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 Nm
200 Nm
30 Nm
60 Nm
15 Nm

Fuel System

13---2

7a
7b
6

Fuel system, description

Fuel feed pump (3) draws fuel from tank (1) through prefilter (2) and forces it through filter (4) to fuel injection pump
(5). The fuel injection pump pumps fuel at high pressure
through the delivery pipes to injectors (6) which inject the
fuel in the form of a fine mist into the combustion chamber.
The fuel system is often equipped with the Thermostart device to be used in cold conditions. The glow plug (8) receives fuel from a separate reservoir (7a) of the thermostart
device or from the overflow valve (9) of the injection pump
regulated by the magnetic valve (7b). Excess fuel returns
from the fuel injection pump through overflow valve (9) to
the fuel tank.

2
1. Fuel tank
2. Prefilter
3. Fuel feed pump
4. Fuel filter
5. Fuel injection pump
6. Injector
7a. Thermostart fuel reservoir
7b. Magnetic valve
8. Glow plug
9. Overflow valve

213--- 1

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 normal operating temperature, it is very likely that
one of the injectors is faulty. Air in the fuel system can also
cause knocking (which should disappear after the system
has been bled of air).
--- Smoky exhaust gases may indicate impaired performance of the injectors. However, this can also be caused by
other faults such as a blocked air cleaner.
The fuel system should always be bled when the fuel system has been emptied (e.g. the fuel tank has been emptied
during driving, in connection with maintenance or repair
work or after a long idle period).

Fuel System

13---3

Bosch ---P injection pump

10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Boost control
Cold start solenoid
Speed lever
Injection timing indicator
Lube oil into the injection pump
Hand pump
O ---ring seal
Return of lube oil to engine
Identification plate
Overflow valve

3
9

4
5

Bosch ---A injection pump

7
8
2

6b

6a

1.
2.
3.
4.
5.
6a.
6b.

Oil filler plug

Speed lever
Hand pump
Lube oil into the injection pump
O ---ring seal
Return of lube oil to engine
Alternative oil return to engine
(e.g. aggregate application)
7. Drive gear
8. Identification plate

5
The injection pump is an in ---line pump and the basic construction is the same in all engines irrespective of the cylinder
number. The fuel injection pump is flange mounted and
sealed by one o---ring in the timing gear casing. The injection
pump is driven from the crankshaft through an idler gear. The
injection pump is connected to the engine force ---feed lubrication system through an external pipe. Lubricating oil returns to the engine via the hole at the front end of the injection
pump. In some versions, specially locally installed engines,
the return of the oil is lead through a hose from the regulator
cover to the crankcase.
The fuel feed pressure which fills the high pressure pump elements with fuel is created by a piston pump which is attached 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 injection pump needs. The excess fuel flows through the overflow
valve back to the fuel tank. The fuel cools the injection pump
and also takes any air bubbles with it back to the tank.

3
213--- 2

Injection pump with the boost control

1. Boost control
2. Cold start solenoid
3. Indicator plug for adjusting injection timing

Fuel System

13---4

The pump element consists of one plunger and one cylinder

which are a matched pair and because of the fine tolerances
the whole element should be changed as a complete unit.
The cylinder has two passages: inlet passage and release
passage. Both passages allow fuel to enter the pressure
space. The side of the plunger has one vertical groove and
one metering edge which are used for adjusting the amount
of fuel injected into the combustion chamber of the engine.
The top of the plunger is provided with a starting groove
(delay groove) which delays the injection timing by approx.
8. (This should be borne in mind when checking the fuel injection timing). This groove improves the cold starting properties of the engine. It works fully automatically. When the engine has stopped the control rod in the injection pump turns
the plungers so that the starting groove faces towards the release passage. When the engine has started and when the injection pump has reached a certain speed, the governor pulls
the control rod back into running position.

213--- 4

1
1. Pressure valve holder
2. Pressure valve
3. Pump element
4. Control rod
5. Return spring for pump plunger
6. Roller tappet
7. Camshaft

2
3
4

The purpose of the fuel injection pump is to meter out fuel to

the combustion chamber at the correct time. Plunger (3)
which is driven by the pump camshaft (7) via roller tappet (6)
forces the fuel through pressure valve (2) and further through
the delivery pipe to the injector.
2

6
7

213--- 6

Pressure valve
1. Holder for pressure valve
2. Valve spring
3. Valve cone
4. Valve guide
5. Valve head
6. Pressure ---reducing piston
7. Vertical grooves

1
The pressure valve is fitted on top of the pump element and
its purpose is to close the connection between the pump element and the delivery pipe. This happens when the metering
edge of the plunger passes the lower edge of the release
passage, thus reducing the pressure in the space above the
plunger. Its second purpose is to reduce the pressure in the
delivery pipe. This is important as it enable the nozzle valve
(needle) to close more quickly.

213--- 5

Two---hole pump element (maximum feed)

A. Bottom dead centre
B. Fuel injection begins
C. Fuel injection ends

1. Inlet passage
2. Cylinder
3. Starting groove
4. Release passage
5. Plunger
6. Metering edge
7. Vertical groove

Pressure valve cone contains a pressure ---reducing piston

which, when the valve closes, is first lowered into the guide
and then closes the connection between the delivery pipe and
the pump element. The valve head is then pressed against its
seat and the fuel in the delivery pipe is given the same space
as the displacement of the pressure ---reducing piston.

Fuel System
Governor

13---5

Fuel injection pump type plate

The injection pump type plate shows one particular letter indicating the user application, see figure below. This letter should
always be quoted when ordering a replacement pump or
when looking for setting values.

4
3

5
6
7

213--- 8
213--- 7

1. Governor weight
2. Control rod
3. Starting spring
4. Main lever
5. Idler screw
6. Governor spring
7. Additional spring, idling
8. Spring for equaliser
9. Governor control arm

The governor is of the centrifugal type and is fitted at the rear

end of the injection pump. The governor controls the rotational speed of the engine throughout the whole speed range,
and identifies the rotational speed by means of the governor
weights. The position of the governor control and of the governor weights is transferred through the governor lever linkage to the control rod. The governor has one governor spring.
Starter spring, which is attached to the upper end of the control lever, it pulls the control rod to the starting position when
the engine stops. This means that the amount of fuel injected
when the engine is started automatically becomes greater.

Fuel System
A. Bleeding fuel system

13---6

B. Bleeding Thermostart system

Always remove air from the glow plug fuel pipe 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

213--- 9

1. Slacken the bleeder screw on the filter head. Pump with the
hand pump until the fuel flowing out at the bleeder screw is
free from air bubbles. Then tighten the bleeder screw.

213--- 11

1. Disconnect the electrical wire from the glow plug and the
fuel pipe.
2. Connect electricity to the magnetic valve and rotate the engine until fuel comes out from the fuel pipe connection.
3. Tighten the pipe connection and connect the electrical wire.
System with a fuel reservoir

1. Reservoir filling
2. To the glow plug
3. Return the fuel tank
4. Breather
213--- 10

3. Slacken the injection pump overflow valve. Pump with the

hand pump until the fuel flowing out is free from air bubbles.
Tighten the overflow.
4. Wipe off any fuel from the engine.

213--- 11/1

1. If the tank is empty fill it first e.g. through the breather.

2. Open the fuel pipe connection to the glow plug and let the
fuel come out. Tighten the pipe.

Fuel System

13---7

C. Measuring fuel feed pressure

E. Changing fuel feed pump valves

1. Clean the fuel injection pump and the filter and the pipes between them.

1. Clean the feed pump. Disconnect fuel pipes to the feed

pump. Remove the feed pump.

213--- 12

2. Fit the gauge at the banjo connection on the pump, as

shown above (between filter and injection pump).
3. Run the engine at low idling for a while and compare the
gauge reading with the prescribed value (0,6...1,0 bar).
Note! If the measured pressure is below the prescribed value,
this may be caused by:
---------

faulty overflow valve

blocked fuel filter
faulty fuel feed pump
blocked or leaking fuel pipes or unions

D. Checking overflow valve

213--- 13

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 connector, in which is placed the pressure valve.
4. Rinse the valves with clean fuel and check the function and
possible wear.
5. Change the valve if needed and assemble the pump using
new o---rings and gasket.
Note! The manufacturer has standardised the pressure valve
A in different feed pumps. The earlier used M20 and M24
tightening threads are replaced by M22 thread (see picture
below). At the same time also the seal rings of the valve are
modified.
29

If the fuel feed pressure deviates from the prescribed value,

check the opening pressure of the overflow valve.

M22 x 1,5

1. Connect a pressure gauge to the banjo union in the same

way as in previous instruction 13 C.
2. Pump with the hand pump until the overflow valve opens.
Compare the reading on the gauge at the moment the valve
opens with the prescribed value (0,6...1,0 bar).

28

32

3. If the recorded opening pressure deviates from the prescribed value, the overflow valve should be changed.

M24 x 1,5

Note! If the recorded pressure is considerably lower than the

prescribed value, there may be a fault in the hand pump or
the fuel feed pump valves.

M20 x 1,5

420, 620/634
213--- 131

320

Fuel System

13---8

F. Checking injection timing

213--- 16

4. Turn the crankshaft to a position where the 1st cylinder piston reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the timing mark on the pulley
(flywheel) passes the timing indicator.
243--- 14

The injection timing for cylinder no. 1 is marked on the crankshaft pulley. The timing indicator can be on the right or left side
of the pulley, depending on engine version. In some tractor
versions the timing mark is on the flywheel.

9025 99000

Note! Due to the automatic excess fuel feed of the injection

pump the control rod must be moved to drive position before
checking the injection timing, otherwise the injection timing
will be 8 incorrect!
1st way of checking
1. Clean the injection pump and its surroundings carefully.
2. In tractor engines remove the inspection hole rubber plug
from the flywheel housing.

213--- 17

5. Remove the protecting cap for the control rod on the injection pump front face. Fit adjusting tool (sleeve for limiting control rod travel) 9025 99000. The tool moves the control rod to
the running position.
6. Disconnect the delivery pipe for the number one cylinder injector at the pump.
7. Clean the delivery valve of fuel. Slowly turn the crankshaft
in the correct direction of rotation until the fuel level in the delivery valve just begins to rise.
8. Check if the mark on the pulley is at the point of the timing
indicator the injection timing is correct. Repeat the check procedure. If the injection pump needs to be adjusted, follow the
instructions under heading 13 G.

9025 99100
213--- 15

3. Insert the locator (9025 99100) in the hole on the flywheel

housing front face.

9. Fit the delivery pipe and the rubber plug in the flywheel
housing. Remove the locator and the sleeve which was used
to limit the control rod travel. Start the engine.

Fuel System

13---9

2nd way of checking

Note! In some types of injection pumps the injection starting
point in the 1st cylinder has been positioned with aid of an
indicator pin in the pump governor housing. Do the inspection
of injection timing as follows:

0 986 612 174

1. Turn the crankshaft to a position where the 1st cylinder piston reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the mark on the pulley passes
the timing indicator. After that rotate the crankshaft slowly to
running direction until the mark on the pulley is at the point of
the timing indicator or the timing mark on the flywheel is at the
point of locator 9025 99100 (see instruction 13 F).
3. Connect the inspection device sensor into the governor
housing. Note the position of the sensor! Connect the ---wire
into earth.
4. Rotate the crankshaft in running direction until light A is on.
5. Continue rotating the crankshaft in running direction very
slowly until light B is on.
6. If the mark on the pulley is at the point, the injection timing
is correct. If the marks are not at the point, preform the adjustment according to instruction 13 G.
213--- 23

2. Unscrew the plug on the side of the injection pump. Take

out the indicator pin.
3. Turn the indicator pin and push it into the hole so that the
groove at the end of the pin points towards the pump.
4. If the pin groove fits on the boss on the governor weight assembly, the injection timing is correct. Otherwise, turn the
pump to a position where the boss and the pin groove align.

G. Adjusting fuel injection timing

If the timing is incorrect, adjust as follows:
1. Loosen the retaining nuts of the injection pump and remove
the delivery pipes.

Note! Do not rotate the crankshaft when the groove end of the
pin is inside the pump, since the pin end damages easily and
plastic pieces remain in the governor housing.
6. When the adjustment is correct, turn the indicator pin so that
the groove points outwards (running position) and push the
pin into the hole. Refit the plug.

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 1st cylinder piston reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the timing mark passes the
dowel pin.
2. Unscrew the plug on the side of the injection pump. Take
out the indicator pin.

213--- 19

2. If the injection timing is retarded, turn the pump anti ---clockwise (viewed from the front end of the pump). If the timing is
advanced, turn the pump clockwise.
3. Check once again the injection timing and set again if
needed.
4. When the timing is correct tighten the retaining nuts of the
pump and fix the delivery pipes.

Fuel System

13---10

H. Removing fuel injection pump

I. Fitting fuel injection pump

1. Clean the injection pump and surrounding engine parts

and the pipes and connectors on the injection pump.

Bosch ---A injection pump

2. Disconnect the delivery pipes and the banjo bolts at the

supply and return fuel connections. Disconnect the lubricating oil line. Plug all connections.

1. Check the condition of the o---ring between the pump and

the timing gear casing. Change the o---ring if necessary.

3. Detach the oil filler pipe/cover from the front cover. Unscrew
the pump drive gear nut.
9052 48900

213--- 21

2. Lubricate the o---ring and place the injection pump so that

the key on the pump shaft aligns with the key slot inside the
gear. Tighten the pump attaching nuts.
Note! The injection pump with adjusting indicator in the covernor housing dont have any key slot in the gear.
213--- 20

4. Use puller 9052 48900 and loosen the gear from the injection pump camshaft front end.
5. Remove the injection pump attaching nuts. Remove the injection pump.

3. Tighten the gear nut to 90 Nm . Fix the oil filler pipe/cover.

4. Connect the supply and return fuel lines. Connect the lubricating oil line. Use new sealing washers.
5. Bleed the fuel system (instruction 13 A).
6. Adjust the injection timing (instruction 13 G).
7. Fit the delivery pipes.

213--- 22

213--- 20/1

8. If the injection pump is changed or if the lubricating oil has

been drained from the pump, fill the pump with lubricating oil
before starting the engine. Open the hexagonal socket plug
on the governor housing and pour in oil.

Note! When removing the Bosch ---P injection pump, open

bottom mounting screws on the both side of injection pump.

Filling quantity:

Note! If the engine is not to be disturbed while the pump is removed, there is no need to secure the pump gear. The gear
rests against the idler gear.

Same oil specification as in the engine.

320---engines 0,3 l
420---engines 0,4 l
620/634---engines 0,6 l

Fuel System
Bosch ---P injection pump
1. Check the condition of the o---rings between the pump and
the timing gear casing. Change the o---rings if necessary.

13---11

Note! In some types of injection pumps the injection starting

point in the 1st cylinder has been positioned with aid of an
indicator pin in the pump governor housing. This type of injection pump is installed as follows:
1. Turn the crankshaft to a position where the 1st cylinder piston reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the mark on the pulley passes
the timing indicator. After that rotate the crankshaft slowly to
running direction until the mark on the pulley is at the point of
the timing indicator or the timing mark on the flywheel is at the
point of locator 9025 99100 (see instruction 13 F).

213--- 22/1
213--- 23

2. Lubricate the o---ring and put the fit ring to the timing gear
casing.
3. Lubricate the o---ring and place the injection pump so that
the key on the pump shaft aligns with the key slot inside the
gear. Tighten the gear nut to 200 Nm and fit the cover.
4. Adjust the injection timing, see instruction 13 G.
5. Connect the supply and return fuel lines. Connect the lubricating oil line. Use new sealing washers. Fit the delivery pipes.
6. Bleed the fuel system, see instruction 13 A.

2. Unscrew the plug on the side of the injection pump. Take

out the indicator pin.
3. Turn the indicator pin and push it into the hole so that the
groove at the end of the pin points towards the pump.
4. Install the injection pump and tighten the installation nuts
and the nut on the gear. Note! The groove for the key has been
left out for the gear.
Warning! Do not rotate the crankshaft when the groove end
of the pin is inside the pump, since the pin end damages easily and plastic pieces remain in the governor housing.
5. When the adjustment is correct, turn the indicator pin so that
the groove points outwards (running position) and push the
pin into the hole. Refit the plug.

Fuel System
J. Checking and changing pressure
valve
1. Clean the injection pump, injectors and surrounding parts.
Disconnect the delivery pipes.
9052 47800

13---12

Note! Replace the sealing ring and o---ring.

8. Tighten the holder as follows:
--- Tighten first to 30 Nm.
--- Open the holder about a turn and tighten to 40 Nm.
--- Open the holder about a turn and tighten to 45 Nm.

K. Adjusting idling speed

If the idling speed of the engine deviates from the value given
in the specifications or if the engine revs vary at the idling
speed, adjust the idling speed as follows:

213--- 24

2. Connect the pressure gauge 9052 47800 to the pressure

valve holder which is to be checked.
3. Rotate the engine with the starter motor, until the gauge reading is about 330 bar.
Note! Pressure rises fast, do not damage the gauge. Get
ready to pull the stop control out as soon as the gauge reading
reaches an adequate pressure value.
4. Let the gauge reading lower at first about 30 bar. When the
gauge shows 300 bar, observe the reading during one minute. During this time the gauge reading must not lower too
much (max 30...50 bar). If the pressure lowers faster than
specified, the pressure valve must be cleaned or replaced.

213--- 26

1. Unscrew the idling speed adjusting nut cap (1) and the cap
(2) on the idling speed additional spring adjusting screw.
2. Ensure that the throttle lever is in the idling position and that
the engine is at normal operating temperature.
3. Start the engine and loosen the adjusting screw of the additional spring so that it does not affect the idling speed.

Note! The pressure valve plunger and guide should always

be replaced in pairs.
5. Open the pressure valve holder locking and holder. Remove the valve spring, plunger and the guide.
6. Rinse the plunger and guide in clean fuel or test liquid and
at the same time rotate the plunger in its guide and press the
sealing surfaces against each other.

213--- 27

4. Adjust the idling speed using the adjusting screw to about

20...30 rpm below rated speed and lock the adjusting screw.
213--- 25

7. Fit the pressure valve into the fuel injection pump. Place the
spring in place and tighten the holder.

5. Run the engine a few times and ensure that the idling speed
remains as set.

Fuel System
6. Tighten the adjusting screw of the additional spring until the
idling speed rises to the rated value. Lock the adjusting screw
in this position.
7. Fix the safety caps of the adjusting screws.
Note! Other adjustments (output and max. speed) of the injection pump can only be performed by a specially trained
person who has the necessary special tools and gauges available.

13---13

M. Inspecting injectors
Note! When pressure testing the injectors, it is important
to avoid the nozzle end as the fuel jetting out easily penetrates the skin. Also bear in mind that the fuel mist is
dangerous to inhale.
1. Clean the injector with cleaning fluid and a soft brush.
The carbon deposits must not be knocked off or removed in
any other way which may damage the nozzle.

L. Removing injectors
1. Clean the injectors and the area around them. Disconnect
the delivery pipes and the leak ---off pipes.

9051 71300

213--- 29

213--- 28

2. Remove the injector attaching nuts and remove the injector

from the cylinder head. Fit protective plugs to all connections.
If the injector does not rise by hand, use puller 9051 71300.
3. Remove the sealing washers from the bottom of the injector
location in the cylinder head if they do no come out with the
injector.

2. Secure the injector in a test bench and check the following:

--- injector opening pressure
--- the properties of the chattering (creaking) sound and the
form of the spray pattern
--- sealing of nozzle valve against its seat

Opening pressure
Pump a few times to fill the injector. Increase the pressure in
the injector until the chattering (creaking) sound becomes
audible. Read off the opening pressure of the injector. If the
opening pressure deviates from the given value, the injector
should be taken apart and checked.
Adjustment is achieved by changing the shim. The thickness
of the shims varies from 1,00...1,90 mm and they are available
in increments of 0,05 mm. A thicker shim will raise the opening
pressure while a thinner one lowers it. A difference in shim
thickness of 0,05 mm changes the opening pressure by approx. 5,0 bar. As the opening pressure of the injector drops
slightly after adjustment, the opening pressure should be set
to approximately 10 bar above the value given in the specifications. This value applies both to new and used injector.

Fuel System
Chattering sound properties

13---14

Testing with a hand powered pump does not create the same
circumstances as when the injector is fitted in the engine. Only
with new 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 design 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 pressure rises to
approx. 20 bar below the adjusting value. Maintain this pressure for approximately 10 seconds and check whether drops
of fuel are formed on the point of the nozzle. If the injector
leaks, it should be cleaned or the nozzle should be changed.

3
4

N. Reconditioning injectors

1. Secure the injector in a suitable way.

2. Unscrew the nozzle cap nut. Remove the nozzle and the
parts inside the holder.

3. Clean the nozzle in cleaning fluid both inside and outside.

4. Clean the nozzle holes with a needle (including in cleaning
set 8360 83288).
5. Test the movement of the nozzle valve as follows:

213--- 31

Injector
1. Fuel inlet
2. Leak ---off fuel
3. Shim
4. Pressure spring
5. Valve stop spacer

6. Nozzle body
7. Pressure chamber
8. Nozzle valve
9. Nozzle hole

6. Before assembling, all parts should be carefully cleaned in

clean fuel or testing fluid.
7. Put the same thickness of shim back as were fitted earlier.
Note possible adjustment of the opening pressure. Assemble
the rest of the injector. Note the position of the spring guide
and the valve stop spacer.
8. Tighten the nozzle cap nut by hand and then to 60 Nm.

213--- 30

Rinse the parts thoroughly in fuel or testing fluid. Pull the valve
out of the nozzle body to 1/3 of its length. If the fit is correct,
the valve should be able to slide down in the nozzle body
under its own weight. Turn the valve slightly and repeat the
test. Should the nozzle valve bind slightly, it should be
changed.

Fuel System

13---15

O. Fitting injector in engine

P. Fitting delivery pipes

1. Clean the injector sealing surface in the cylinder head. If

necessary use a reamer 9101 66000.

1. Check the state of the pipes. If there are kinks, damage by

chafing, or if the tapered sealing end is damaged, the pipes
should be changed.
2. Fit the pipes without tension and check that they are at right
angles to the union.
3. Fit the clamps for the pipes.

1
2

213--- 32

1. Washer
2. Rubber ring
3. Sealing washer

2. Fit the injector in the cylinder head using a new sealing

washer.
Note! The spray pattern from the injector is not symmetrical
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 be finger tight. If tools have to be used the studs
should be tightened only lightly.
Note! Make sure, that the injector is of a correct type. Wrong
injectors cause malfunctions and can damage the engine.

Fuel System

13---16

CAV DISTRIBUTOR PUMP

2
Some 420--- and 620---engines are having a CAV made
DPA ---type distributor pump. The pump is equipped with an
electrical solenoid (ignition key starting and stopping) and
automatic bleeding system. The internal lubrication of the
injection pump is done by the fuel it is pumping. The separate feed pump, of diaphragm type, is driven by the camshaft of the engine. The system is also equipped with a Thermostart---device that receives the fuel through the fuel filter.

213--- 33

1. Installation marks of injection pump

2. Overflow flange
3. Throttle lever
4. Stop lever
5. Stop solenoid
6. Identification plate

TECHNICAL DATA
Injection pump CAV
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection order
420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DPA
1---2---4---3
1---5---3---6---2---4
clockwise
see pump installation marks

Fuel feed pump

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diaphragm pump, separate hand
lever
Fuel feeding pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 bar (48 kPa)
Fuel feeding pressure min. (used pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 bar / max. rpm

Injectors CAV
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control pressure (new injector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control pressure (used injector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

five ---hole nozzle

250+8 bar
230+8 bar
8999 01495

Tightening torques
Pump gear retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Nozzle retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Injector retaining nuts (for the studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Fuel System
A. Dismounting and mounting injection pump
1. Clean the pump and the surrounding parts carefully.
Remove the delivery pipes, the throttle cable wire from the
revolution lever and the stop solenoid wire from the pump.
Fit protective caps on the delivery pipe unions.

13---17

B. Injection pump gear

The engines equipped with a rotary injection pump have a
different timing mark on the gear in 420--- and 620---engines.

2. Remove the cover of the front covering so that the pump

gear wheel becomes accessible.
3. Unscrew the gear wheel attaching nut. Detach the gear
wheel by using puller 9052 48900.
Note! If the timing gear casing has not been removed, the
injection pump gear wheel remains in contact with the idler
gear and it is unnecessary to mark the positions of the
gears.
4. Detach the injection pump from the timing gear casing.
Clean the sealing surfaces.
5. Place a new sealing ring on the pump flange. Push the
pump into place so that the key on the shaft engages with
the key slot on the gear wheel.

213--- 35

To identify the gear, in 620---engines the gear has a machined groove shown in the picture. In 420---engines the
gear does not have this groove. The gears must not be
mixed with each other.

C. Bleeding fuel system

Note! This fuel system removes automatically small
amounts of air bubbles from the filter and the pump when
the engine is running. However, bleed the system always,
when the system has been opened or fuel has been
exhausted during driving or a new spare pump has been
fitted (to avoid long starting time).
Bleed the fuel filter
213--- 34

6. Tighten the pump into position, where the timing marks

align.
7. Tighten the gear wheel nut to a torque of 90 Nm. Fasten
the pump gear wheel covering.
8. Remove the protective caps from the delivery pipe unions and fit the delivery pipes. Fit the overflow pipe, throttle
cable wire and the stop solenoid wire. Bleed the fuel system (see instruction C).

213--- 36

1. Pump by hand the fuel feed pump lever. If the pumping

seems to be ineffective, turn the engine a little so that the
camshaft cam is not at the feed pump lifter.

Fuel System

13---18

Bleed the thermostart system

Always remove air from the glow plug fuel pipe 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.
1. Open the pipe adaptor of the glow plug.
2. Pump with the hand pump until the fuel is running out of
the pipe adaptor.
3. Tighten the pipe adaptor. Clean the engine of leaked fuel.

213--- 38

2. Unscrew the bleed screw on the top of the fuel filter

3. Pump with the hand pump until the fuel running out of
the bleed screw is free of air bubbles.
4 Close the bleed screw. Clean the engine of leaked fuel.
Bleed the injection pump
1. Turn the ignition key to the position ON (stop solenoid is
opening)

D. Feed pump
The feed pump of diaphragm type is not supplied with
spare parts separately, replace the complete pump if the
feed pressure is very low (min. 0,20 bar/max. rpm) or the
pump has otherwise been damaged.

E. Injector
The inspection and reconditioning of the injector is mainly
done in the instruction 13 L...O on pages 13 ---13...13 ---15.
The difference is opening pressure and the adjusting
shims.
The new injector has a opening pressure of 250+8 bar. An
used injector has a opening pressure of 230+8 bar.
The adjusting shims are delivered with a 0,02 mm difference, from 0,42 to 0,70 mm thickness. Also 0,30, 1,00, 1,28
and 1,56 mm thick shims are available. A difference of 0,02
mm in the shim thickness changes the opening pressure
about 2 bar.
Note! Ensure that always the correct nozzle type is used,
because an incorrect nozzle leads to incorrect function of
the engine and damages.

213--- 37

2. Unscrew the bleed screw on the top of the injection

pump.
3. Pump with the hand pump until the fuel running out of
the bleed screw is free of air bubbles.
4. Close the bleed screw. Switch off the current. Clean the
engine of leaked fuel.

Fuel System

13---19

STANADYNE DISTRIBUTOR PUMP

Note! This manual gives only general instructions for repair
and service measures related to the fuel system. This
applies particularly to the injection pump which can be repaired only by a specially trained person who has the
necessary special tools and gauges. All service and repair
work related to the fuel system requires special care and
cleanliness!

TECHNICAL DATA
Injection pump Stanadyne
Type:
--- DB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (two pressure plungers)
--- DB 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (four pressure plungers)
Injection order:
--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- 620/634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1---2---3
1---2---4---3
1---5---3---6---2---4
Clockwise
see pump installation marks

Fuel feed pump

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diaphragm pump, separate hand
lever
Fuel feed pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 bar (48 kPa)
Fuel feed pressure min. (used pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 bar / max. rpm

Injectors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 14---10
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495
Tightening torques
Pump gear retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Nozzle retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Injector retaining nuts (for the studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Fuel System

13---20

Fuel system with distributor pump

213--- 40

In this fuel system, there is a separate fuel feed pump (3)

on the RH side of the engine.
The system includes a separate prefilter (2) and a fuel filter
(4). The lower parts of the fuel filter housings have a space
for possible impurities and there is a draining tap under
both filter housings.
The fuel feed pump has a washable filter. There is also a
tapered metal net filter inside the distributor pump in the
inlet line before the pump transfer pump.
The fuel system is often equipped with the Thermostart device to be used in cold conditions. The glow plug (9) receives fuel from a separate reservoir (8) of the thermostart
device or from the overflow valve of the injection pump
regulated by the magnetic valve.

1. Fuel tank
2. Prefilter
3. Fuel feed pump
4. Fuel filter
5. Distributor pump
6. Injector
7a,b,c. Return fuel to tank
8. Thermostart reservoir
9. Glow plug
10a,b. Bleeding screws
11. Valve of reverse back flow

Fuel System

13---21

Stanadyne---distributor pump
F
5

213--- 40/1

1 2
D

1.
2.
3.
4.
5.
6.

Type plate with pump order number

Timing marks under the cover
Fuel inlet
Return fuel/overflow valve
Revolution lever
Connector for wire to electric stop solenoid

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

A. Interrupted screw (order no 8366 59038)
B. Timing sensor
C. Fuel Limiter FL
The fuel limiter FL restricts the injection mostly at low
RPM as the air ratio otherwise would be too low.
D. Light Load Advance LLA
Adjustment of the injection advance according to the rotating speed and load steered by the fuel delivery pressure after the metering valve.
E. Aneroid Control AC
The aneroid control regulates fuel delivery to match
turbocharger air flow characteristics at low speeds to
minimize smoke during acceleration on low speed.
F. Boost pressure

G. Compact Cold Advance CCA

Electrical device for earlier injection advance at start and
low load (under 1100 RPM) to minimize the so called cold
smoke. The device includes an injector pump solenoid
and a separate control unit to follow the engine rotating
speed.

Fuel System
Stanadyne distributor pump

13---22

1. Drive shaft
2. Governor weights
3. Governor spring
4. Stop solenoid
5. Overflow valve
6. Metering valve
7. Cam ring rollers
8. Hydraulic head
9. Pressure regulator valve
10. Transfer pump blades
11. Distributor rotor
12. Pressure valve
13. Cam ring
14. Automatic advance
15. Centrifugal governor
16. Pumping plungers

213--- 41

Construction
The main rotating components are the drive shaft, transfer
pump blades, distributor rotor and governor.
The drive shaft engages the distributor rotor in the hydraulic
head. The drive end of the DB2 rotor incorporates two
pumping plungers and DB4 four.
The plungers are actuated toward each other simultaneously by an internal cam ring through rollers and shoes
which are carried in slots at the drive end of the rotor. The
numbers of cam lobes normally equals the number of cylinders (not 3---cyl. engines).
The transfer pump at the rear of the rotor is of the positive
displacement vane type and is enclosed in the end cap.
The end cap also houses the fuel inlet strainer and transfer
pump pressure regulator. The face of the regulator assembly is compressed against the liner and distributor rotor and
forms an end seal for the transfer pump.
The injection pump is designed so that end thrust is against
the face of the transfer pump pressure regulator.

The distributor rotor incorporates two charging ports and a

single axial port (pressure chamber), in which is placed the
pressure valve. After the delivery valve, there is one discharge port to serve all head outlets to the fuel injection
pipes.
The hydraulic head contains the bore in which the rotor
revolves, the metering valve bore, the charging ports and
the connections to the fuel injection pipes.
The pump contains a mechanical governor. The centrifugal
force of the weights is transferred to the metering valve via
a linkage. The metering valve can be closed electrically with
aid of the solenoid in the pump housing.
The automatic advance is a hydraulic mechanism which
turns the cam ring and advances or retards the beginning
of the fuel delivery from the pump.

Fuel System

13---23

Stanadyne distributor pump

Housing pressure
Transfer pump pressure
1. Fuel tank
2. Water trap
3. Fuel feed pump
4. Fuel filter
5. Transfer pump
6. Pressure regulator valve
7. Automatic advance
8. Air vent passage
9. Stop solenoid

Injection pressure

213--- 42

10. Regulator spring

11. Centrifugal weights
12. Overflow valve
13. Hydraulic head connecting passage
14. Metering valve
15. Hydraulic head charging pasage
16. Distributor rotor
17. Pressure valve
18. Injector

Function
The fuel feed pump draws fuel from the tank via the water
trap and the filter into the fuel injection pump.
In the pump fuel flows through the inlet filter screen into the
vane type fuel transfer pump. Some fuel is bypassed through
the pressure regulator assembly to the suction side.
Fuel under transfer pump pressure (1---6 bar) flows through
the center of the transfer pump into the circular groove on
the rotor. It then flows through a connecting passage in the
head to the automatic advance and up through a radial
passage and then through a connecting passage to the
metering valve. The metering valve adjusts amount of
injected fuel and position of the metering valve is controlled by the governor (revolution lever) and the stop solenoid. From the metering valve fuel flows to the radial charging passage and further to the head charging ports.
As the rotor revolves, the two rotor inlet passages register
with the charging ports in the hydraulic head, allowing fuel
to flow into the pumping chamber. With further rotation, the
inlet passages close and the port to the injectors opens.

While the discharge post is opened, the rollers contact the

cam lobes forcing the plungers together. Fuel trapped
between the plungers is then pressurised and delivered by
the nozzle to the combustion chamber.
The injection pump is self ---lubricating, and it has not been
connected to the engine lubrication system.
As fuel at transfer pump pressure reaches the charging
ports, slots on the rotor shank allow fuel and any entrapped
air to flow into the pump housing cavity. In addition, an air
vent passage in the hydraulic head connects the outlet side
of the transfer pump with the pump housing. This allows air
and some fuel to be bled back to the fuel tank via the overflow valve.
The fuel thus bypassed fills the housing, lubricates the
internal components, cools and carries off any small air
bubbles. The pump operates with the housing completely
full of fuel; there are no dead air spaces anywhere within
the pump.

Fuel System

13---24

A. Removing pump
1. Clean the pump and the surrounding parts carefully.
Remove the delivery pipes, the throttle cable wire from the
revolution lever and the stop solenoid wire from the pump.
Fit protective caps on the delivery pipe unions.
2. Remove the cover of the front covering so that the pump
gear wheel becomes accessible.
3. Unscrew the gear wheel attaching nut. Detach the gear
wheel by using puller 9052 48900.
Note! If the timing gear casing has not been removed, the
injection pump gear wheel remains in contact with the idler
gear and it is unnecessary to mark the positions of the
gears.
4. Detach the injection pump from the timing gear casing.
Clean the sealing surfaces.
Note! In E ---engines have one retaining screw so---called interrupted screw. Unscrew it with a drift.

B. Fitting injection pump

adjusting injection timing

and

213--- 44

2. Remove the small cover plate on the side of the injection

pump. Rotate the pump shaft until the timing marks align
(see arrow in picture above).
3. Place a new sealing ring on the pump flange. Push the
pump into place on the timing gear housing. Note! key
groove in gear left out from beginning of 1996.
4. Tighten the pump into position, where the timing marks
align.
5. Tighten the gear wheel nut to a torque of 90 Nm. Fit the
small cover onto the side of the pump. Fasten the pump
gear wheel covering (+oil filler tube).
6. Remove the protective caps from the delivery pipe unions and fit the delivery pipes. Fit the overflow pipe, throttle
cable wire and the stop solenoid wire. Bleed the fuel system (see instruction C).

213--- 43

1. Turn the crankshaft to a position where the 1st cylinder

piston reaches its compression stroke top dead centre.
Then turn the crankshaft backwards until the mark on the
pulley passes the timing indicator. After that rotate the
crankshaft slowly to running direction until the mark on the
pulley is at the point of the timing indicator.
Note! Distance between the piston top face and the top
dead center with different crankshaft angles, see page
5 ---3.

Note! Lubrication oil is not needed because fuel in the

pump lubricates the internal parts.

Fuel System

13---25

C. Bleeding fuel system

D. Fuel feed pump

Note! This fuel system removes automatically small

amounts of air bubbles from the filter and the pump when
the engine is running. However, bleed the system always,
when the system has been opened or fuel has been
exhausted during driving or a new spare pump has been
fitted (to avoid long starting time).

For the membrane type fuel feed pump no spare parts are
supplied. The feed pump must be changed for a new one,
if the feed pressure has dropped noticeably (min. 0,20 bar/
max. rpm) or if the fuel feed pump has been damaged.
Note! From engine number H 6794 have engines provide
with new type fuel feed pump. New pump is fixed to cylinder block with four screws instead of the previous two. The
new pump can be used as spares also to earlier made engines using repair kit 8366 62052, see Service information
no 50 98.

Measuring fuel feed pressure

--- Clean the injection pump, filter and all fuel pipes.
--- Connect a pressure gauge between the filter and the injection pump, connect the pressure gauge to the inlet pipe
in the middle of the injection pump rear end (point B in the
previous instruction).
213--- 45

1. Pump by hand the fuel feed pump lever. If the pumping

seems to be ineffective, turn the engine a little so that the
camshaft cam is not at the feed pump lifter.

--- Allow the engine to run at the idling speed and read off
the fuel feed pressure in the pressure gauge.
Note! If the feed pressure value is below the rated value,
possible reason can be:
--- blocked fuel filter/fuel feed pump metal gauze filter
--- faulty fuel feed pump
--- blocked or leaked fuel pipes or pipe connections
Important! Under the fuel feed pump cover there is a
washable filter. If much impurities have gathered on this
filter, fuel cannot flow to the feed pump and further to the
injection pump and this causes malfunctions in the fuel system. Always when malfunctions appear, the feed pump
cover should be removed and the metal gauze filter must
be checked and cleaned.

E. Injectors
213--- 46

2. Loosen the bleeding screw A on the filter. Pump with the

hand pump until no air bubbles flows out of the bleeding
screw hole. Tighten the bleeding screw.
3. Pump further with the hand pump and loosen the fuel
inlet connection B on the pump, until the fuel coming out is
free from air bubbles. Tighten the connection.
4. Start the engine and assure, that no leaks exist.
Note! When the bleeding is done in this way, fuel flows
immediately into the internal transfer pump when the starter
motor is rotating and the distributor pump housing is filled
quickly with fuel. In the pump housing there is a stop solenoid, which must not be switched on for longer periods
when the pump housing is empty of fuel.

Injectors are checked and serviced according to instructions 13 L...O on pages 13 ---13...13 ---15.
Opening and setting pressures of the injectors are on page
14 ---10.
Adjustment is achieved by changing the shims. The thickness of the shims varies from 1.00...1,90 mm and they are
available in increments of 0,05 mm. A thicker shim will raise
the opening pressure while a thinner one lowers it. A difference in shim thickness of 0,05 mm changes the opening
pressure by approx. 5,0 bar. As the opening pressure of the
injector drops slightly after adjustment, the opening pressure should be set to approximately 10 bar above the value
given in the specifications. This value applies both to new
and used injector.

Fuel System
F. Adjusting low idling speed

13---26

H. Wiring diagram of electrical advance (CCA)

Ignition switch
1

+
Red 1,5 mm2

Alternator

W
(R)

Green 1,5 mm2

213--- 47

Control unit
+
W
OUT
---

Blue 1,5 mm2

1. Low idling speed

2. Revolution lever
3. Max. revs

Brown 1,5 mm2

The low idling speed can be adjusted with a limiting screw

in front of the revolution lever. The adjusting screw for max.
revs has been sealed. This adjustment has been done in
the factory, and adjustment of max. revs afterwards is prohibited.

Stop solenoid

Note! The throttle cable is attached to the revolution lever

lower hole. To the upper hole is fastened a return spring.

Injection pump

Other information

213--- 48

The injection pump housing upper cover has been sealed

to prevent adjustment of engine output afterwards. Also the
stop solenoid is fitted under this cover. It is recommended,
that all pump repairs are made by an authorised Stanadyne
workshop.

G. Bleeding Thermostart system

Always remove air from the glow plug fuel pipe 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.
1. If the reservoir is empty, fill it e.g. with a drip pot through
the breather hole on the reservoir.
2. Open the glow plug pipe connector and drain fuel from
the pipe. Connect the pipe.

The control unit of the electrical advance depends on gear

ratio of the alternator.
SPARE PART
NO

GEAR
RATIO

ALTERNATOR

8368 54777

2.32

12 V MM

8368 54778

2.90

12 V Delco

8368 54817

3.97

12 V Valeo

Fuel System

13---27

I. Checking injection timing (dynamic)

B

213--- 49

1. Warm up engine and fuel injection system.

display to read R=___ Set RPM.

Note! All connections, including the magnetic probe insertion

and removal, must be done with the engine stopped.

Note! Before starting engine, make certain that all cables are
clear of any moving parts or hot manifold.

2. Remove the protective plug from access hole ( 8 mm) and

attach the magnetic probe assembly A to the engine by inserting the probe into the access hole (in tractor versions into the
upper hole), and the RETRACTING SLIGHTLY (0,5...1,0
mm). This must be done to prevent wear of the end of the
probe caused by contact with the flywheel. Connect the magnetic probe cable to the meter socket MP.

8. Once the proper RPM is displayed, press ENTER. The display shows Calibrating... for a short period of time.

3. Install the adapter clamp B by first placing the clamp assembly around sensor slightly above the brass contact ring
and then moving down over the contact ring. Tighten the
thumb screw of the clamp ensuring that the end of the screw
contacts the ring. Connect the transducer cable to the meter
socket SR. Connect the alligator clip to some clean unpainted
metallic portion of the fuel system or engine.
4. Turn the meter on by pressing the ON/CLEAR key. The
words Time Trac and thenModel TT 1000 should appear
briefly followed by R= 0. The meter can be used as a tachometer at this point without further manipulation.
5. Press MAG PROBE. Display shows Trig Level 30%. Press
ENTER leaving the trigger point at 30%.
6. Display shows Offset 20.0. Press ENTER leaving the
offset at 20,0.
7. Display shows Calibrate?. Start the engine and run it at
low idle speed. Press ENTER to continue which will cause the

Note! If for some reason the meter loses the engine speed signal or the engine is not running, the display will show Eng.
Not running, flash this message 3 times, and return to the tachometer mode. To restart the procedure, press MAG PROBE
(point 5).
9. If for example the engine were running at 850 RPM and timing were 6 BTDC, display should now read R=850 MP +
6.0. Now the meter is ready for use.
Note! If for some reason the meter loses the magnetic probe
signal the display will show R=850 No Probe. Once the
magnetic probe signal is restored, the display will show the
proper timing reading.
10. You can measure the pump timing at high idle speed [TT
(HI)]. This value is valid for pump timing setting. Adjust if
necessary. The cam advance operation of the injection pump
you can check at low idle [TT (LI)].
Setting values are available through Service Department of
Sisu Diesel Inc.
Read also manufacturer service manual.

Fuel System
Trouble shooting
If the timing deviates remarkably from given, check the following:
1. Vibrating delivery pipe, hold the pipe with hand.
2. Distance of magnetic probe from flywheel not correct, re --set the magnetic probe.
3. Offset or Trig Level value wrong, re ---set.
4. Disturbing scratches on the flywheel.
5. Alignment of flywheel---crankshaft wrong, remove the flywheel and reassemble correct.

13---28

Fuel System

13---29

Fuel quality requirement

Density, +15C

Requirement

Test method

0,82...0,86 kg/dm3

ASTM D 4052, EN ISO 12185

mm2/s

ASTM D 445, ISO 3104

Viskosity, +40C

1,2...4,5

Sulphur content

max. 0,2 % m/m

ASTM D 4294, ISO 8754

Cetane index

min. 45

ASTM D 4737

Water content

max. 200 mg/kg

ASTM D 1744

The fuel should be according to norm EN 590.

OUTPUT %
+5

Engine output depending on fuel quality

Different fuel qualities like temperature, density and viscosity

affect the actual output of the engine. Our output rates use fuel
with a density of 0.84 kg/dm3 and specific heat rate of 42,7 Mj/
kg at a fuel temperature of +15C.
The correction in % caused by the change of fuel qualities is
seen in the attached figures.

OUTPUT %
+5

---5

0,84
0,90
0,85
DENSITY kg/dm3

0,80

FIG. B. Engine output dependence on fuel density. Normal

value is 0,84 kg/dm3 at +15C.

OUTPUT %
+5
---5

35
10

20

30
40
50
60
FUEL TEMPERATURE C

FIG.A. Engine output dependence on fuel temperature.

+35C is the reference temp (correction 0 %).
The fuel temperature is not only a function of ambient conditions but also varies according to the fuel system of the application (tank size and location, return flow etc.).

0
---2
2

7
8
6
VISCOSITY cSt

FIG. C. Engine output dependence on fuel viscosity. Normal

value is 3 cSt at +20C.
Note fig. B and C only if the fuel quality is changed. In fig. A
there are all the quality dependencies caused by the change
of the temperature. The fuel density and viscosity can be seen
in the produce declaration given by the manufacturer.
The output correction is made as follows: Correction percentages from figures A, B and C are summed up. The given rated
power is then corrected with the resulting percentage.

Valmet 455

Valmet 555

Aggregate

320 DS

320 DS

320 DG

8366 40382
13.250/1

8366 40156
13.230

8366 40197
13.223/1

8366 40198
13.202/1

PES 3A 95D
320 RS 2810
/D
RSV 375---750
A2C 2178---10R

RSV 375---1175
A2C 2178---10R

PES 3A 95D
320 RS 2810

PES 3A 95D
320 RS 2810
/A
RSV 375---1175
A2C 2178---10R

PES 3A 95D
320 RS 2810
/B
RSV 375---1175
A2C 2178---10R

21
1500
1570
33

19
2350
750
53

19
2350
750
49

21
2350
750
45

78---80

10---15

94---96

10---15

79---81

12---15

79---81

12---15

740
750
760
770
780

1175
950
800
500
375

1150
1000
800
500
325

1150
950
800
500
325

82---84

11---16

94---96

11---16

82---84

13---16

73---88

13---16

101---103

Valmet 355

PES 3A 95D
320 RS 2810
/C
RSV 375---1150
A2C 2178---10R

1150
1000
800
500
375

320 D

8366 40199
13.222/1

102---104

Valmet 6100

320 DS

19
2300
750
58

Injection advance
Feed rate
Max. output r/min
mm3/stroke
Idling r/min
ISO 4010
ISO 7440
rpm
mm3
Output kW
mm3

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

320

10,9...11,3
10,9...11,3
8,6...9,0
6,1...6,5
3,8...4,2

11,3...11,7
11,3...11,7
12,0...12,4
11,9...12,5
4,1...4,7

10,0...10,4
+0,2...0,3
+0,5...0,6
+0,5...0,6
4,1...4,7

10,7...11,1
11,1...11,5
11,6...12,0
11,6...12,0
4,1...4,7

12,1...12,5
+0,1...0,2
+0,3...0,4
+0,3...0,4
4,1...4,7

RW mm

754---756

1200

1200---1220

1200

1170---1190

Control rod
min.
---1 mm
rpm

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

778---782

1255---1285

1270---1300

1280---1300

1240---1260

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8367 54532

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

Element
Pressure valve
Covernor spring

Equipment and Feeding Table

14---1

Valmet 6400

Valmet 6600

Hymax 8200

420 DS

420 DS

420 D

8367 40200
14.209

8367 40173
14.228/1

8367 40157
14.227/1

8367 40174
14.226/1

PES 4A 95D
320 RS 2807
/S
RSV 375---1000
A2C 2178---7R

PES 4A 95D
320 RS 2807
/A
RSV 375---1125
A2C 2178---7R

RSV 375---1125
A2C 2178---7R

PES 4A 95D
320 RS 2807

PES 4A 95D
320 RS 2807
/B
RSV 375---1125
A2C 2178---7R

21
2000
750
60

19
2225
750
77

19
2225
750
70

19
2225
750
63

11---15

83---84

11---15

98---100

11---15

84---87

11---15

82---84

11---15

1000
800
600
375

1100
1000
900
800
500
375

1100
1000
900
500
375

1100
1040
800
500
375

11---15

87---88

11---15

101---103

11---15

91---93

11---15

87---89

11---15

77---78

Valmet 6300

PES 4A 95D
320 RS 2807
/BE
RSV 375---1175
A2C 2178---7R

1150
1000
900
600
375

420 DS

8367 40392
14.212

73---74

Valmet 665
4600

420 D

21
2350
750
59

Injection advance
Feed rate
Max. output r/min
mm3/stroke
Idling r/min
ISO 4010
ISO 7440
rpm
mm3
Output kW
mm3

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

420

11,1...11,3
0,1
0,1
3,9...4,5

12,3...12,7
0,2
+0,4
+0,5
0,5
4,2...4,5

11,2...11,6
+0,3...0,4
+0,5...0,6
+0,5...0,6
4,2...4,5

10,7...11,1
10,9...11,3
11,2...11,6
11,2...11,6
4,2...4,5

9,8...10,2
+0,4...0,5
+0,8...0,9
+0,8...0,9
3,9...4,5

RW mm

1030---1050

1140---1150

1135---1145

1130

1195---1205

Control rod
min.
---1 mm
rpm

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

1090---1110

1200---1220

1210---1230

1200---1210

1270---1285

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

Element
Pressure valve
Covernor spring

Equipment and Feeding Table

14---2

Wille 725

Wille 745/
845

Valmet 836
838

420 D

420 DS

420 DSI
DW

8367 40180
14.235/1

8367 40201
14.241

8367 40202
14.210

8367 40181
14.202/1

PES 4A 95D
320 RS 2807
/H
RSV 325---1100
A2C 2178---7R

PES 4A 95D
320 RS 2807
/T
RSV 375---1200
A2C 2178---7R

PES 4A 95D
320 RS 2807
/U
RSV 375---1100
A2C 2178---7R

PES 4A 95D
320 RS 2807
/J
RSV 375---1200
A2C 2178---7R

19
2200
750
82

19
2200
750
80

21
2200
750
60

21
2400
750
62

11---15

101---103

11---15

97---99

11---15

77---78

11---15

76---78

1000
800
500
325

1100
800
500
375

1100
800
500
375

1200
1100
1000
900
500
375

11---15

101---103

11---15

98---100

11---15

82---83

11---15

78---80

11---15

104---106

Wille 645
Joonas
Lnnen C15

11---15

1000
800
600
375

420 D

PES 4A 95D
320 RS 2807
/V
RSV 375---1000
A2C 2178---7R

104---106

Hymax 8200T 8367 40203

14.242

420 DS

19
2000
750
80

Injection advance
Feed rate
Max. output r/min
mm3/stroke
Idling r/min
ISO 4010
ISO 7440
rpm
mm3
Output kW
mm3

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

420

12,2...12,6
12,2...12,6
12,2...12,6
4,0...4,4

12,1...12,5
0,1
0,1
3,9...4,5

10,5...10,7
0,1
0,1
4,5...5,1

9,6...9,8
+0,1...0,2
+0,2...0,3
+0,4...0,5
+0,4...0,5
4,3...4,7

12,6...13,0
0,1
0,1
4,0...4,4

RW mm

1120---1135

1125---1140

1125---1140

1230---1150

1030---1050

Control rod
min.
---1 mm
rpm

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

1185---1200

1185---1210

1185---1210

1290---1310

1190---1210

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

Element
Pressure valve
Covernor spring

Equipment and Feeding Table

14---3

Lnnen C20
C100
C200
James 73
83

Lnnen S30
M213
T214
M314
T315

Lnnen M215 8367 40179

M316 14.233/1

420 DS

420 DS

420 DSI

8367 40178
14.232/1

8367 40176
14.230/1

8367 40386
14.270/1

PES 4A 95D
320 RS 2807
/G
RSV 325---1000
A2C 2178 R

PES 4A 95D
320 RS 2807
/F
RSV 325---1000
A2C 2178 R

PES 4A 95D
320 RS 2807
/D
RSV 375---1200
A2C 2178---7R

PES 4A 95D
320 RS 2807
/BD
RSV 375---750
A2C 2178---7R

19
2000
650
80

19
2000
650
70

19
2400
750
82

19
1480
1560
64

11---15

110---112

14---17

94---96

11---15

99---101

106---108

11---15

1000
800
600
325

1000
800
600
500
325

1200
800
500
325

740
750
760
770
780

11---15

110---112

14---17

97---99

11---15

101---103

107---109

11---15

102---104

Aggregate

PES 4A 95D
320 RS 2807
/BF
RSV 375---1200
A2C 2178---R

1200
1100
1000
900
700
325

420 DSG

8367 40399
14.237/1

101---103

Valmet 828
836
838
840
901
Marine

420 DW
DSM

19
2400
650
84

Injection advance
Feed rate
Max. output r/min
mm3/stroke
Idling r/min
ISO 4010
ISO 7440
rpm
mm3
Output kW
mm3

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

420

13,1...13,5
0,0
0,0
4,0...4,4

12,1...12,3
0,0
0,0
0,0
4,2...4,6

12,3...12,5
0,1
0,1
3,9...4,5

12,8...13,2
11,6...12,0
9,0...9,4
6,3...6,7
3,8...4,2

12,4...12,8
+0,1...0,3
+0,3...0,5
+0,5...0,6
+0,5...0,6
4,0...4,4

RW mm

1025---1040

1025---1035

1225---1240

748---750

1230---1240

Control rod
min.
---1 mm
rpm

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

1085---1110

1085---1110

1285---1310

777---780

1330---1350

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8353 31163

8353 31161
8353 39126
8367 54532

8353 31161
8353 39126
8353 31163

Element
Pressure valve
Covernor spring

Equipment and Feeding Table

14---4

Lnnen C15

420 DS

8367 54501
14.249

PES 4A 95D
320 RS 2807
/BU
RSV 375---1200
A2C 2178---7R

PES 4A 95D
320 RS 2654
/PK
RSV 325---1200
A2C 2218 R

19
2400
750
74

19
2400
650
90

11---15

86---88

95---98
12---15

95---97

1200
800
500
375

1150
1000
800
700
500
800
325

12,8...13,2
0,1
0,1
4,0...4,4

RW mm

1220---1235

Control rod
min.
---1 mm
rpm
1285---1300

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8353 31163

Element
Pressure valve
Covernor spring

11---15

90---92

11,1...11,3
0,1
0,1
3,9...4,5

1225---1240

1285---1310

8353 31161
8353 39126
8353 31163

11,6...12,0
1215---1225 1290---1310 8353 31161
+0,1
8353 39126
+0,3
8353 31163
+0,4
Boost control operation
1,0
+0,4
start at 0,45 bar (declining pressure)
0,0
11,8...12,0
0,0
4,8...5,0
*) boost pressure regulators pressure bar

1,0(*
1,0
1,0

11---15

106---108

Ponsse S 15e 8367 40162

14.236

11---15

1200
800
600
375

420 DSI

PES 4A 95D
320 RS 2807
/R
RSV 375---1200
A2C 2178---7R

106---108

Ponsse S 15e 8367 40194

14.240

420 DWI

19
2400
750
90

Injection advance
Feed rate
Max. output r/min
mm3/stroke
Idling r/min
ISO 4010
ISO 7440
rpm
mm3
Output kW
mm3

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

420

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

Equipment and Feeding Table

14---5

MF 3670
VA 66 SB

Dr 8400
MF 30

Dr 8700
MF 32
32 RS

620 DS

620 DSL

620 DSL

8368 40195
16.233

8368 39976
16.223

8368 40193
16.232/1

8368 40158
16.203/1

PES 6A 95D
320 RS 2806
/DA
RSV 500---1100
A0C 2178---9R

PES 6A 95D
320 RS 2684
/CO
RSV 325---1110
A0C 2178 2R

RSV 500---1100
A0C 2178---9R

PES 6A 95D
320 RS 2806

RSV 375---1150
A0C 2178---8R

PES 6A 95D
320 RS 2806

21
2200
1000
129

21
2200
1000
110

21
2200
1000
125

23
2225
750
88

116---118
20---24
12---15

x=1,5---2 R

90---93
18---22
11---14

12---15

101---103

12---15

73---75

13---16

1100
1150
500

900
1150
500

1100
1000
900
790
500
500

1100
980
800
500
375

113---115
21---25
12---15

92---95
19---23
11---14

12---15

100---102

12---15

77---79

13---16

64---66

Valmet 8100

PES 6A 95D
320 RS 2806
/F
RSV 325---1125
A0C 2178---8R

1100
950
700
375

620 D

8368 40210
16.205

61---63

Valmet 8000

620 D

23
2220
750
72

Injection advance
Feed rate
Max. output r/min
mm3/stroke
Idling r/min
ISO 4010
ISO 7440
rpm
mm3
Output kW
mm3

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

620

12,5...12,9
4,0...4,3
4,0...4,4

10,4...10,8
3,8...4,2
4,0...4,4

11,4...11,6
+0,3...0,4
+0,4...0,6
+0,5...0,6
+0,5...0,6
3,7...4,1

8,9...9,1
+0,3...0,4
+0,8...0,9
+0,8...0,9
3,8...4,2

7,6...8,0
8,3...8,7
8,8...9,2
4,0...4,4

RW mm

1110---1115

1105---1110

1130---1140

1120---1130

1150---1160

Control rod
min.
---1 mm
rpm

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

1155---1165

1148---1157

1170---1190

1190---1215

1190---1210

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8353 31780

8353 31161
8353 39126
8353 31780

8353 31161
8353 39126
8353 31780

8353 31161
8353 39126
8353 31780

8353 31161
8353 39126
8353 31780

Element
Pressure valve
Covernor spring

Equipment and Feeding Table

14---6

Aggregate

Aggregate

620 DG

620 DSG

8368 54502
16.274/2

8368 40421
16.250/1

8368 40152
16.230

PES 6A 95D
320 RS 2806
/DT
RSV 500---1100
A0C 2178---9R

PES 6A 95D
320 RS 2806
/DN
RSV 740---900
A0C 2178---9R

PES 6A 95D
320 RS 2832
/A
RSV 375---1250
A0C 2218---1R

21
1500
1570
110

23
1760
1570
81

x=5,0 R

21
2500
800
132

1250
1000
600
600
LDA
500
500
375
11---15

102---104

107---109

12---15

12,4...12,5
12,2...12,3
3,7...4,3

12,4...12,8
0,0
0,0
12,0...12,1

9,8...10,2
0,0
0,0
3,8...4,2

RW mm

130---132

700
740
750
760
770
780

850
900
910
920
930
940

133---135

71---73

13,9...14,3
14,0...14,2
13,1...13,5
9,8...10,2
6,4...6,8
3,0...3,4

9,8...10,2
8,6...9,0
7,3...7,7
6,0...6,4
4,6...5,0
3,3...3,7

boost pressure regulators pressure bar

67---69

*)

0,50
0,45
0,0

0,8(*
0,8
0,8
0,0

12---15

86---87

Sisu ---Masi
SA 130

PES 6A 95D
320 RS 2806
/DI
RSV 375---1100
A0C 2178---9R

1100
800
500
375

620 DSA

8368 40230
16.238

83---85

VA 66S

620 DSP

21
2200
750
106

Injection advance
Feed rate
Max. output r/min
mm3/stroke
Idling r/min
ISO 4010
ISO 7440
rpm
mm3
Output kW
mm3

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

620

748---750

897---899

1270---1290

1130---1140

Control rod
min.
---1 mm
rpm

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

776---778

936---938

1340---1360

1180---1190

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8368 54727

8353 31161
8353 39126
8367 54532

8353 31161
8353 39126
8353 31780

8353 31161
8353 39126
8353 31780

Element
Pressure valve
Covernor spring

Equipment and Feeding Table

14---7

8368 40398
16.237

PES 6A 95D
320 RS 2806
/DE
RSV 375---1200
A0C 2178---9R

1200
1000
800
700
500
12---15
390
x=12 NAPS, 4,5 R

96---98

12---15

97---99

Valmet 860
911

620 DS

21
2400
780
130

Injection advance
Feed rate
Max. output r/min
mm3/stroke
Idling r/min
ISO 4010
ISO 7440
rpm
mm3
Output kW
mm3

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

620

11,5...11,9
11,6...12,0
12,0...12,4
12,2...12,6
12,2...12,6
3,7...4,3

RW mm

1130---1140

Control rod
min.
---1 mm
rpm

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

1170---1190

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8353 31163

Element
Pressure valve
Covernor spring

Equipment and Feeding Table

14---8

8368 54524
18.223
RSV 500---1100
A5C 2269---R

PES 6A 95D
320 RS 2848

PES 6A 95D
320 RS 2806
/EG
RSV 500---1125
A0C 2178---8R

20
2200
1000
140

1100
1000
900
800
750
600
375
11---13

86---88

ISO 7440
mm3
9,8...10,2
9,9...10,3
10,1...10,5
10,2...10,6
10,3...10,7
10,3...10,7
3,8...4,2

RW mm

1115

1130

Control rod
min.
---1 mm
rpm

Nozzle ISO 4010 173 bar or

nozzle ISO 7440 207 bar
0,60 orifise plate

1100
120---122 13,8...14,2
1000
13,9...14,3
900
14,1...14,5
800
14,2...14,6
750
14,3...14,7
600
14,3...14,7
LDA
0,65
500
14,0...14,4
0,42
500
12,4...12,8
0,0
500
12,2...12,6
500
16---19
6,5...7,5
*) boost pressure regulators pressure bar

1,0(*
1,0
1,0
1,0
1,0
1,0

Steyr 9190A
MF 3690

634 DS

8368 54570
18.201

22
2225
750
96

Valmet 8200

634 D

rpm

Feed rate
mm3/stroke

Injection advance
Max. output r/min
Idling r/min
Output kW

Pump spare part no Pump

Fuel adjustment card Governor

Application

Engine

634

Test equipment ISO 4008

Fluid ISO 4113
Pipes 6 x 2 x 600 ISO 4093

FUEL SYSTEM
EQUIPMENT AND FEEDING TABLE

1180---1200

1190---1210

Control rod
position
4 mm
rpm

8353 31161
8353 39126
8353 54532

8353 31161
8353 39126
8353 31780

Element
Pressure valve
Covernor spring

Equipment and Feeding Table

14---9

Stanadyne

Stanadyne

Stanadyne

Stanadyne

Stanadyne

Stanadyne

Stanadyne

CAV

8363 40034

8368 40397

8368 54786

8368 54755

8368 54791

8368 54831

8366 59808

8366 40167

Type

8366 40165

8366 59902

8368 54832

8368 54792

8368 54757

8366 39957

8368 40396

8363 39985

8366 39957

Nozzle no.

270
278
278
278
278
250+8

270+8
270+8
270+8
270+8
230+8

240

240

240

Setting pressure bar 1)

260

230

230

230

Opening pressure bar

Value to be used when adjusting the opening pressure of a new or used injector.

Stanadyne

8366 39956

1)

Manufacturer

Order no.

FUEL SYSTEM
INJECTOR

358

446

876

423

780

105

655

736

Code (C)

8366 40337...8366 40355 (0,30...1,57 mm) ---

8368 62000...8368 62020

8368 62000...8368 62020

8368 62000...8368 62020

8368 62000...8368 62020

8366 40104...8366 40122

8366 40104...8366 40122

8366 40104...8366 40122

8366 40104...8366 40122

Adjusting plate no. 1,00...2,00 mm

Equipment and Feeding Table

14---10

Electrical System

15---1

15. ELECTRICAL SYSTEM

A. Alternators
Magneti Marelli A 127 45 A/65 A
(Lucas)

(Sisu Diesel no. 8366 40127 45 A)

(Sisu Diesel no. 8366 40128 65 A)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Max. voltage 6000 r/min . . . . . . . . . . . . . . . . . . A 127 45 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 A
A 127 65 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 A
Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (---) minus
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 000 r/min
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,7 N
Number of stator poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Number of stator phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . A 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
2

3
4
5

A 127

CAV AC 5 RS 24 V 55 A

45 A
65 A

AC 5 RS

(Sisu Diesel no. 8353 39422)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Output
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A
3000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42,5 A
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 A
Charge begins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 r/min
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 000 r/min
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,23 N
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,0...8,3 ohm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,09 ohm
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm

215--- 1

Electrical System
Bosch N1 28 V 10/80 A

15---2

(Sisu Diesel no. 8353 39751)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output
1500 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2700 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Assembling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Regulator screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Joint B--- (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Joint W (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Joint D+ (M4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5

24 V
16 A
53,5 A
79 A
26,8 mm
19 mm
5 mm
7,5...8,2 ohm
0,057...0,062 ohm
28 V
55 Nm
4,1...5,5 Nm
1,6...2,3 Nm
4,8...6,8 Nm
2,7...3,8 Nm
1,6...2,3 Nm
7,5...8,0 Nm
1 4

4
3

2
7
3

7
2

80 A
Bosch N1 28 V 0/100 A

100 A

215--- 2

(Sisu Diesel no. 8353 40374)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output (warm generator, testing voltage 26 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3500 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Assembling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Regulator screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Joint B--- (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Joint W (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Joint D+ (M4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 V
26 A
72 A
94 A
26,8 mm
19 mm
5 mm
7,5...8,2 ohm
0,038...0,041 ohm
28,5 V
70 Nm
4,1...5,5 Nm
1,6...2,3 Nm
4,8...6,8 Nm
2,7...3,8 Nm
1,6...2,3 Nm
7,5...8,0 Nm

Electrical System
Iskra AAK 5118 14 V 95 A

15---3

(Sisu Diesel no. 8366 40927)

(Sisu Diesel no. 8366 66225)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output (testing voltage 13 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge begins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Joint B+ (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Joint W (M 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 V
50 A
84 A
94 A
1100 r/min
15 000 r/min
15,3 mm
5 mm
2,7...2,97 ohm
0,33...036 ohm
50...70 Nm
4,2...6,0 Nm
2,7...3,8 Nm
2,7...3,8 Nm

2
3

215--- 3

Bosch NC 14 V 70 ---120 A

(Sisu Diesel no. 8368 40939)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output (13,5 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge begins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques (see figure above):
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch NC 14 V 150 A

12 V
79 A
111 A
120 A
1200 r/min
12 000 r/min
14,9 mm
12,5 mm
5 mm
60...70 Nm
10 Nm
5 Nm

(Sisu Diesel no. 8368 64048)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques (see figure above):
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 V
14,9 mm
12,5 mm
5 mm
60...70 Nm
10 Nm
5 Nm

Electrical System

15---4

B. Starters
Magneti Marelli M 127/2,8 12 V
(Lucas)

(Sisu Diesel no. 8353 31592)

Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5500...8000 r/min (max.)
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 V
Values, under loading
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 r/min (max.)
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,0 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,8 Nm
Values, locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1160 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,0 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,4 Nm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,6...15,5 N
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm
Min. 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

2
1

0,14 ... 1,14

5 4
Bosch JF (R) 24 V 4kW
Bosch JF (R) 24 V 4 kW, 2 ---pole

Magneti Marelli

(Sisu Diesel no. 8353 30965)

(Sisu Diesel no. 8361 30388)

Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >7000 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <85 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 V
Values with armature locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900...1050 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,5 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >65 Nm
Solenoid engaging voltage min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 V
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 mm
Min. commutator diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42,5 mm
End play of armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1...0,3 mm

215--- 4

Electrical System
Iskra AZJ3234 12 V 3,1 kW z11

(Sisu Diesel no. 8366 40949)

Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Values with armature locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush length (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. commutator diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques:
1. Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Screws on solenoid (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Screws on solenoid (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever pin on engagement lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact screws on solenoid switch (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact screws on solenoid switch (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Iskra AZJ3247 12 V 3,6 kW z11

15---5

10 000 r/min
140 A
11 V
0 r/min
1660 A
5,6 V
45 Nm
23 mm
13 mm
40...48 N
43,5 mm
5,8 Nm
3,2 Nm
6,0 Nm
37 Nm
3,2 Nm
12 Nm
8,5 Nm
13 Nm

(Sisu Diesel no. 8366 40940)

Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Values with armature locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush length (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. commutator diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques:
1. Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Screws on solenoid (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Screws on solenoid (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever pin on engagement lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact screws on solenoid switch (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact screws on solenoid switch (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 000 r/min
140 A
11 V
0 r/min
1756 A
5,3 V
47 Nm
23 mm
13 mm
40...48 N
43,5 mm
5,8 Nm
3,2 Nm
6,0 Nm
37 Nm
3,2 Nm
12 Nm
8,5 Nm
13 Nm

Electrical System
Iskra AZJ3319 12 V 3 kW z10

15---6

(Sisu Diesel no. 8366 40949)

Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Values with armature locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush length (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0 r/min (max.)
1375 A
51 Nm
23 mm
13 mm
30...35 N

Tightening torques:
Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screws on solenoid (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screws on solenoid (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever pin on engagement lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact screws on solenoid switch (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact screws on solenoid switch (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5,8 Nm
3,2 Nm
6,0 Nm
37 Nm
3,2 Nm
12 Nm
8,5 Nm
13 Nm

Iskra AZJ3256 24 V 4 kW z11 2 ---pole

8000 r/min
90 A

(Sisu Diesel no. 8366 64355)

Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Values with armature locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush length (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0 r/min (max.)
1200 A
70 Nm
23 mm
13 mm
30...35 N

Tightening torques:
Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screws on solenoid (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screws on solenoid (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever pin on engagement lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact screws on solenoid switch (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact screws on solenoid switch (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5,8 Nm
3,2 Nm
6,0 Nm
37 Nm
3,2 Nm
12 Nm
8,5 Nm
13 Nm

10 000 r/min
80 A

Electrical System

15---7

C. Electric stop device

FASTENING TO INJECTION PUMP

Loctite 242

Assembly
1. Solenoid
2. Thread sleeve
3. Rubber bad
4. O ---ring
5. Screw
6. O ---ring
7. Parts to be removed

Loctite 242
2

Electrical connection

87

86
85

10 A

1. Solenoid
2. Relay
3. Fuse
4. Battery
5. Starter
6. Ign. switch
7. Fuse

30

1
Johdin
Wire
Kabel

2,5 mm 2

215--- 5

* Relay control voltage must not break during engine cranking.

--- Max. wire length with 2,5 mm2 wire:
--- 2,7 m 12 V system
--- 10,4 m 24 V system
--- It is not allowed to connect any other power consuming
devices to the solenoid feed lines.
--- Voltage drop in wiring should not exceed 7 % of rated
voltage when pull coil is activated.

Electrical System
FASTENING TO BRACKET

15---8

A. Connect a voltmeter or a suitable lamp between the solenoid positive pole and AUX---pole. When the current is
switched on and the solenoid moves to the end of its motion
range, the voltmeter reading should indicate approximately
battery voltage or the light should be on. If such is not the
case, adjust the leverage or change the position of the solenoid.

Checking the solenoid operation (Synchro start)

25,4

215--- 6

The solenoid plunger has 25,4 mm motion range. Fix the solenoid and adjust the leverage in such a way that the energised
plunger will reach its lock position.
Following are the methods to establish the solenoid plunger
being in its lock position when the current is switched on.

B. Before attaching the drawing lever or the bar, press the

plunger in until it is complete down. Measure the solenoid
length, e.g. from bottom plate edge to a suitable spot on the
plunger rod. Fix the leverage and energise the solenoid.
Measure the length again and ensure it remains unchanged.
Testing the external circuit of the solenoid
Measure the voltage between the positive and negative poles
of the solenoid when the current is on and the draw coil draws.
At the same time measure the voltage between the battery
poles. The voltage difference may not exceed 7 % of battery
voltage.
Note! Operating the solenoid more than six times within a
minute may result in overheating of coils.

AUX

215--- 7

Checking the solenoid operation (Elettrostart)

A Running position
B Stop position

For a correct use of the dual coil solenoid (pull coil and hold
coil) the plunger should reach the end of its magnetic stroke
at each pulse. In this way, it will press the internal switch which
connects the continuous operation second hold coil working
without over ---heating and with a minimum power absorption.
1. Fit the solenoid energized and adjust the leverage in such
a way that the stop lever will reach its position or running position (stop solenoid energized during running).
Note! Energize the solenoid through a battery with suitable
voltage and keep it energized during installation.

Electrical System
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
215--- 8

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 pick up end is 0,75 mm from the tooth.
Note! Clean the pick up end from dirt in the yearly service.

E. Temperature sensor
2

215--- 9

1. Connection for warning light

2. Connection for temperature gauge
Gauge monitoring resistances:
60C . . . . . . . . . . . 134 13,5 ohm
90C . . . . . . . . . . . 51,2 4,3 ohm
100C . . . . . . . . . . . 38,5 3,0 ohm
Part no.

Alarming temperature

6542 71208

983C

8366 40772

1063C

8366 64017

1103C

15---9

Optional Equipment

16---1

16. OPTIONAL EQUIPMENT

A. Compressor (Bendix)
A

B
7

C
G
10
11

2
1

9
12
140 Nm
E

13

A. Cylinder head retaining screws

B. Cylinder head
C. Valve plate
D. Ventil plate retaining screws
E. Cover
F. Bottom cover
G. Valve seat
H. Crankcase
Note! The numbered parts (1...13) are included in the repair
kit.

216--- 1

1. Inlet valve heads

2. Spring
3. Valve guide
4. Gasket
5. Delivery valve heads
6. Spring
7. Gasket
8. Air filter
9. Gasket
10. Unloader saddle and spring
11. Piston
12. O ---ring
13. Gasket

DISASSEMBLY
1. Remove the retaining screws (A, 11 pcs.), take off the cylinder head and the valve plate. Remove the inlet valve heads,
springs, valve guides and gasket.
2. Loosen the retaining screws (D, 2 pcs.) and detach the cylinder head from the valve plate. Remove the delivery valve
heads, springs and gasket.
3. Remove the retaining screws of the air filter (if assembled)
and take off the filter and the gasket.

4. Remove the unloader spring and saddle as well as the pistons and the o---rings seals.
5. If necessary, remove the rear end cover and its o---ring seal
and the bottom cover with its gasket.
Note! Do not try to remove the valve seats. They are pressed
in during manufacture and are integral parts of the crankcase.

Optional Equipment
INSPECTION

16---2

B. Compressor (Knorr)

1. Thoroughly clean all removed parts. Ensure that all air and
water passages are clear. Clean off any carbon from the piston heads and the cylinder top parts.
12 Nm

2. Check the condition of the inlet and delivery valve seats.

Only slight, even wear is permitted. If the delivery valve seats
show considerable wear, renew the valve plate. If the inlet
valve seats are excessively worn, replace the crankcase. You
can also replace the inlet valve seats, but then you need to rebore the cylinders after the new seats have been fitted.

130 Nm

Note! There are two oversize pistons supplied for the compressor. The oversize are 0,254 mm and 0,508 mm. Bore the
cylinders then to the dimensions 75,254 mm or 75,508
mm.
3. Ensure that the new unloader pistons are a good sliding fit
in their guides. If the guides are appreciably worn, renew
them.

2,5...3,0

4. Check the bearings for wear and replace them, if necessary.

If needed, the slide bearing in the end cover can be renewed.
0,1...0,4
REASSEMBLY
1. Fit a new o---ring seal in its groove and place the end cover
in its position by pushing from the back. Tighten the cover retaining screws evenly to 17...23 Nm.
2. Fit the bottom cover with a new gasket in place (if removed).
Tighten the cover retaining screws evenly to 8...10 Nm.

22 Nm

80 Nm

3. Insert new o---rings in the unloader pistons. Lubricate the

o---rings and the piston guides lightly with e.g. silicone lubricant. Fit the pistons in their guides and reassemble the unloader saddle and spring. Ensure that the unloader mechanism moves freely.

30 Nm

4. Fit the delivery valve heads and springs into the valve plate.
Insert a new gasket and fix the valve plate in the cylinder head.
Tighten the screws to 5,4...8,1 Nm. Ensure that the valve
heads move freely. DO NOT LUBRICATE THE VALVE
HEADS OR SPRINGS!
5. Fit the inlet valve head guides into their recesses with the
cut---away sides towards their respective cylinder bores. Assemble the inlet valve heads and the springs. Fit the cylinder
head using a new gasket. Tighten the retaining screws evenly
to 20,3...23,0 Nm. Ensure that the valve heads move freely.
DO NOT LUBRICATE THE VALVE HEADS OR SPRINGS!
6. Attach the air filter (if necessary) and use a new gasket.

22 Nm
22 Nm

22 Nm

60 Nm
216--- 2

Optional Equipment
C. Industrial clutch (A.P. Borg &
Beck)
SERVICE
Note! Never service or adjust the clutch with the engine
running.

16---3

ADJUSTMENT
The clutch is correctly adjusted when the engagement load at
the end of the operating lever is 34...41 kg (operating lever
length 63,5 cm).
Adjusting rings of the clutch

4
3

216--- 4

1. Remove the inspection cover and release the adjuster lock

on the red adjusting ring.

216--- 3

1. Inspection cover
2. Pull---out hole
3. Grease nipple for release bearing
4. Grease nipple for main bearing

1. Lubricate the release bearing daily and the main bearing at

intervals of 50 running hours. Use lithium ---based grease for
lubrication (e.g. Shell Alvania no. 2).
2. At intervals of 500 running hours lubricate the wrist pins, the
yoke ends and the cross shaft bearings with a few drops of engine oil.

216--- 5

Note! Some clutches have a socket headed screw to lock the

adjusting ring. Remove the screw before adjusting. After adjustment tighten the screw to 13,5...18 Nm and ensure that
the inner end of the screw engages between the splines on
the body.
2. Turn the adjusting ring clockwise by hand or by tapping with
a light hammer, until the correct adjustment is reached.
3. Fit the adjuster lock and the inspection cover.

Optional Equipment
Adjusting the main bearing
The tapered roller bearings on the drive shaft must be adjusted when the shaft end play exceeds 0,25 mm.

max.
A 0,25 "

3
1. Lock plate
2. Tapered roller bearings
3. Adjusting ring
216--- 6

1. Remove the inspection cover and take off the lock plate.
2. Using a soft metal drift turn the adjusting ring towards the
bearing, until the drive shaft end play is 0,10...0,20 mm. One
notch of the adjuster is equivalent to about 0,09 mm bearing
movement.
Note! The bearing will be overloaded and will run hot, if all end
play is eliminated. After adjustment ensure that the shaft end
play is sufficient (0,10...0,20 mm).
3. Replace the lock plate and the inspection cover.
Removing the power take ---off from the engine
1. Disconnect the drive from the clutch and remove the pulley/
coupling and the shaft key.
2. Support the weight of the power take ---off with e.g. chain
hoist. Remove the clutch operating lever.
3. Loosen the clutch retaining screws. The clutch housing
flange has pull---out holes (thread BSF). Place screws in
the holes and tighten them one half of a turn at the time alternately, until the clutch housing is removed from its spigot.

16---4