SISU Service Information

V837079421
4th Generation Engines
Instruction Manual
11 01
AGCO SISU POWER Inc.

FI-37240 Linnavuori, Nokia, Finland
Telephone: +358 3 341 7111
E-mail: info@agcosisupower.com
www.agcosisupower.com
Diesel Engines, After Sales

Telefax: +358 3 341 7333
AGCO SISU POWER Inc. takes no responsibility for any damages caused
because of possible incorrect information in this manual
CONTENTS
TO THE USER
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ENGINE TYPE DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
LOCATION OF THE ENGINE SERIAL NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
MARKING OF THE EEM4 CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
LIFTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CONSTRUCTION
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SCR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
OPERATION AND DRIVING

DAILY PRE-START CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
COLD START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ATTENTION DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
COUPLING ADDITIONAL EQUIPMENT TO THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . .23
SERVICE
PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
COMMISSIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
SERVICES TO BE MADE DAILY OR AT 10 HOURS INTERVALS . . . . . . . . . . . . . . . . . . . . .26
SERVICES TO BE MADE WEEKLY OR AT 100 HOURS INTERVALS . . . . . . . . . . . . . . . . . .27
SERVICES TO BE MADE AT 500 HOURS INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
SERVICES TO BE MADE AT 1000 HOURS INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
SERVICES TO BE MADE AT 4000 HOURS INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
SERVICES TO BE MADE ONCE A YEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
SERVICES TO BE MADE EVERY TWO YEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
ADDITIONAL SERVICE INSTRUCTIONS

BLEEDING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
BEFORE THE COLD SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
LUBRICATING OIL QUALITY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
COOLANT QUALITY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
FUEL QUALITY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
EEM4 ENGINE CONTROL SYSTEM FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
READING THE EEM4 FAULT CODES USING A SIGNAL LIGHT . . . . . . . . . . . . . . . . . . . . . .49
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
To the User
TO THE USER
The purpose of this manual is to familiarise you with the use and maintenance of your AGCO Sisu Power
4th Generation engine and give you the basic technical data and settings relating to its construction. Be-
fore using the engine carefully read the operating, service and safety instructions to ensure your engine
runs in the most economic way.
When contacting the Service Organisation, please state the engine type and the serial number.
4th Generation engines meet the emission requirements set by authorities (EU97/68/EC Stage lllB and
EPA 40 CFR 89 Tier 4i). The manufacturer guarantees that all engines of this type are equivalent to the
engine that is officially approved. This must be noticed especially when performing periodical mainte-
nance, follow carefully the service schedule. Any adjusting and repair work for the injection system or
the engine control unit can only be made by a representative authorized by AGCO SISU POWER Inc.
When performing any service or repair work use only original AGCO Sisu Power/SisuDiesel spare parts.
Inadequate or delayed service and the use of other than original AGCO Sisu Power/SisuDiesel spare
parts invalidates the responsibility of AGCO SISU POWER Inc. on the fulfilment of the emission require-
ments.
We reserve the right to change the adjustment settings, equipment and also the service and repair in-
structions of the engines without further notice. Unless otherwise stated, the instructions and settings
apply to all variants of 4th Generation engines.
The engine is guaranteed according to AGCO SISU POWER terms of warranty 8366 62489.
Please fill your engine data here
Engine type
Engine serial number
Date of commissioning
1
To the User
SAFETY INSTRUCTIONS
In the use and service of the engine there is always the possibility of injury. Before
starting the service read and understand the following safety instructions and re-
marks!
When you are operating the engine or working near it, use hearing protectors to avoid noise impacts.
If you start the engine indoors, be sure to have proper ventilation.
Never use aerosol type of starting aid! (Risk for explosion, personal injuries and engine damage!)
Start the engine only by using the starting switch in the cabin.
Stop the engine always before service or repair work.
Open fire, smoking and sparks should not be allowed near the fuel system and batteries. (Specially
when loading batteries, explosive.)
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 in contact with skin.
Avoid touching the exhaust manifold, turbocharger and the other hot parts of the engine.
Always disconnect the negative (-) battery cable when servicing or repairing the electric system.
Do not open high pressure pipe connectors of the fuel system when the engine is running. Wait at
least 30 sec. after stopping the engine. If the jet of high pressure fuel contacts your skin, fuel pene-
trates the skin causing severe injuries. Get medical help immediately!
Keep the engine surfaces clean in order to avoid the risk of fire.
At temperatures on excess of 300°C, e.g. if the engine is burnt by a fire, the viton seals of the engine
(e.g. the undermost o-ring of the cylinder liner) produce very highly corrosive hydrofluoric acid. Do
not touch with bare hands, viton seals subjected to abnormally high temperatures. Always use neo-
prene rubber or heavy duty gloves and safety glasses when decontaminating. Wash the seals and
the contaminated area with a 10 % calcium hydroxide or other alkaline solution.
Put all removed material in sealed plastic bags and deliver them to the point stated by the Authorities
concerned. NOTE! Never dispose of viton-seals by burning!
The fuel, lubricating oil and coolant cause irritation in long time skin contact.
If for example welding or similar high current work is done for the application, it is recommended to
disconnect EEM4 control unit main connector and SCR supply module connector before working.
Do not let oil and other liquids to the environment when servicing the engine. Take them to a proper
disposal point.
Avoid unnecessary idling of the engine.
All the gaskets of the engine are of non-asbestos material.
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.
2
To the User
ENGINE TYPE DESIGNATIONS
74 A W I G
G = generating set engine
M = marine engine
C = Centurion engine
Equipped with intercooler
I = air to air
Turbocharged engine
W = by-pass turbo
T = standard turbo
Basic type
74 = cylinder displacement, decilitres
A = aftertreatment system
LOCATION OF THE ENGINE SERIAL NO.
The engine serial number is always stamped on the cylin-

der block as the picture shows. Manufacturer
AGCO SISU POWER Inc.
FIN-37240 Linnavuori
FINLAND
The serial number is also marked on the type plate. Type ASP 74 AWI
e17*97/68HA*2004/26*0033*00
regulations large nonroad compression

Power 135 kW 2200 rpm
This engine conforms to199 U.S EPA

4th Generation engines have an electronic serial number Serial nr
Valve
data which is readable with EEM 4 service tool. The data in- clearance 0,35 mm
Timing
TDC SW degrees
cludes also detailed specification, operation history and Low idle 650 rpm
ignition engines
service information. Cust.
Part nr N 5903820
EU
Family D45FSH
EPA
Family ASIDL08.4H6A
Displacement: 7.4 l Fuel: 2-D fuel oil
Assembled by:
R07575
66/74/84/98
M07576
33/44/49
3
To the User
MARKING OF THE EEM4 CONTROL UNIT
The specification of the application is indicated on the type

plate of the EEM4 control unit. This specification must al-
ways be stated when ordering a control unit or asking for
adjusting settings.
NOTE! The engine meets EU97/68/EC Stage lllB and EPA

40 CFR 89 Tier 4i emission requirements.
Do not fit any components on the engine other than those

originally intended for it. The use of other than original AGCO SISU POWER Inc.
AGCO Sisu Power/SisuDiesel spare parts invalidates the
responsibility of AGCO SISU POWER Inc. on the meeting EEM 4
of the emission requirements.
Engine X10000
Serial No.
Specification
No. 84.500
ECU
Serial No. 123456789
LIFTING THE ENGINE
Safe lifting of the engine is done with a lifting device where the lifting force affects
the lifting eyes vertically.
Weight of Engine
A A
Engine Weight
type kg *)
33 300
44 345
49 345
66 515
74 525
84 665
98 790
*) Approximate dry weight without flywheel, electrics,

CCV and SCR system components
A = Engine lifting eyes
4
Construction
CONSTRUCTION
TECHNICAL DATA
Engine Type 33 44 49 66 74 84 98
Principal Dimensions
and Data
Number of cylinders 3 4 4 6 6 6 7
Displacement (ltr) 3,3 4,4 4,9 6,6 7,4 8,4 9,8
Cylinder bore (mm) 108 108 108 108 108 111 111
Stroke (mm) 120 120 134 120 134 145 145
Combustion Direct injection
Injection advance Automatic adjusted
Valve clearance, intake and 0,35 (cold or hot)
exhaust (mm)
Direction of rotation from the Clockwise
engine front
Fuel System
High pressure pump Bosch CP 4.1 or CP 4.2
Fuel The fuel must be according to norm EN 590:2009,
see page 41
Injection order 1-2-3 1-2-4-3 1-5-3-6-2-4 1-2-4-6-7-5-3
Injector Bosch CRIN 3 or CRI2.2, electronic control
eight-hole nozzle
Injection pressure Max.1800 bar when CP 4.2 high pressure pump
Injection pressure Max.1600 bar when CP 4.1 high pressure pump
Fuel filters
Pre-filter Donaldson 10 µ
Final filter Donaldson 2 µ
Lubrication System
Oil pressure in hot engine at running speed 2,5...5,0 bar
Oil pressure at idle speed, min 1,5 bar
Oil capacity see page 29
Oil quality requirements see page 40
Cooling system
Number of thermostats 1 1 1 1/2 2 2 2
Opening temperature ∅ 54 mm = 79°C ∅ 67 mm = 83°C
Coolant quality requirements see page 41
5
Construction
GENERAL
The 4th Generation engine series consists of water-cooled in-line diesel engines. The turbocharged
engines are equipped with wet, changeable cylinder liners. The whole fuel system is located on the
cold side of the engine. The engines are equipped with an electric pre/post heater of intake air.
The general arrangement of the equipment is shown in the pictures on pages 6 - 7.
3 4 5
2
1 6
16
15 7
8
10 9
11
13 12
14
Sisu Power 44 AWI
1.Turbocharger
2.IWastegate
3.Inlet air heater solenoid
4.Inlet air heater
5.Fuel filters
6.Hand pump
7.Oil cooler / Oil filter
8.Speed sensor (crankshaft)
9.Coolant draining plug
10.Oil pressure regulating valve
11.Electronic control unit (ECU)
12.Oil dipstick
13.Oil pressure sensor
14.High pressure pump
15.Rail
16.Coolant temperature sensor
6
Construction
M 1001
Sisu Power 74 ATI
1.Turbocharger
2.Oil filler plug
3.Hydraulic pump
4.Belt tightener
5.Alternator
6.Starter
7.Breather
7
Construction
AIR INTAKE SYSTEM
The air intake system includes the pre-filter (or cyclone, if installed), air filter, turbocharger, intercool-
er, inlet manifold and air pipes. A mechanical or electric sensor can be fitted to indicate the service
point of the air filter. If the engine is operating in very dusty conditions (for example spreading lime)
it must be equipped with a special pre-filter and oil bath air filter.
Turbocharger
The turbocharger is a turbo-compressor driven by exhaust gas. The compact design of the turbo-
charger is fast to react even at low engine speeds. The turbocharger is lubricated and cooled by the
lubrication system of the engine.
Cooling of Inlet Air (ATI-engines)
The compressed air is cooled on the air-to-air basis. The air coming from the turbocharger has a tem-
perature of abt. 150°C which is cooled by the cooling air of the engine. The intercooler cell is ideally
installed in front of the radiator or side-by-side with radiator. The cooling of the compressed air sta-
bilises the combustion, irrespective of the temperature, and minimises the thermal and mechanical
load of the engine thus lowering nitric oxides (NOx) and particles (PT).
8
Construction
FUEL SYSTEM
4th Generation engines are equipped with common rail system which is controlled by EEM4 electronic
control unit.
10
8
2
6
5
11
1
7
3
4
Parts of Fuel System
1. Fuel tank 7. High pressure pump

2. Hand pump 8. Rail
3. Pre-filter 9. Overflow valve
4. Fuel filter 10. Injector
5. Temperature sensor 11. Pressure sensor
6. Feed pressure sensor
Fuel is drawn from the tank via the pre-filter, through the main fuel filter to the high pressure pump. From
the high pressure pump, fuel is pumped up into the rail. This high pressurized fuel is lying in a high pres-
sure pipe where it is controlled and injected through electronic injectors that are controlled by EEM4. The
injection is optimized in terms of emissions, efficiency and operation noise and takes place in four steps
(maximum). Excess fuel returns from the injectors and pressure regulating valves of the high pressure
pump and rail back to the fuel tank.The overflow pipe from the filter helps the bleeding of the system.
The fuel is diesel fuel according to the norm EN 590:2009 and it must be clean and free from water after
storage (see fuel quality requirements, page 41).
NOTE! Use of anti-freeze solution is not allowed and not useful at all!
Water is removed from the system by draining the water trap periodically and by cleaning the fuel tank
before frost season (see also actions before winter, page 39).
Do not open high pressure pipe connectors of the fuel system when the engine is
running. Wait at least 30 sec. after stopping the engine. If the jet of high pressure fuel
contacts your skin, fuel penetrates the skin causing severe injuries. Get medical help
immediately!
9
Construction
ENGINE CONTROL SYSTEM EEM4
6 13 15
10
12 14
8
3 5 4 9
7
16
2 1
11 SCR System
Engine CAN
Parts of Engine Control System
1. Electronic control unit (ECU) 11.Vehicle connector

2. Oil pressure sensor 12.Inlet air heater
3. Speed sensor (camshaft) 13.Inlet air heatersolenoid
4. Coolant temperature sensor 14.Heater wiring
5. Rail pressure sensor 15.Fuse
6. Boost pressure sensor 16.Water detector (fuel)
7. Fuel temperature sensor
8. Fuel pressure sensor
9. Speed sensor (crankshaft)
10.Injector wiring
The basic function of the electric control of the engine is continuous adjustment and measuring of the
load, quantity of fuel and rotating speed. Other additional functions are for example cold start auto-
matics, engine protecting automatics and SCR system control. The central unit of the electric control
receives continuous signals from sensors that measure different functions in the engine like rotating
speed, oil pressure, boost pressure, coolant and fuel temperature. The control unit receives the rel-
evant information about the engine load need from the transmission or cabin through the CAN bus.
The EEM4 unit makes it also possible to have a wide diagnostics through code numbers or a diag-
nostic light.
10
Construction
LUBRICATION SYSTEM
The engine has a pressure lubrication system with the gear oil pump fitted to the lowest level of the en-
gine. The oil pump is driven by the gear at the front end of the crankshaft.
Nearly all the lubrication points and auxiliary equipment are connected to the pressurised lubrication sys-
tem by oil galleries or pipes. The lubrication of the gears in the gear housing, the upper end of the con-
necting rods and the pistons is mainly realized by splash lubrication.
The undersides of the pistons of the high output engines are always cooled by the oil spray when the oil
pressure is more than 3 bar.
All 4th Generation engines are equipped with closed crankcase ventilation (CCV) system, which is of
centrifugal oil separator type on 84 and 98 engines, Super Impactor type with boost air on high power
44, 49, 66 and 74 engines and impactor type on 44 and 33 engines. All types of CCV systems are main-
tenance-free.
7 3
5 6
Lubrication System
1. Oil pump
2. Oil pressure regulating valve
3. Oil filter
4. Turbocharger
5. Main oil gallery
6. Piston cooling nozzle
7. Oil pressure sensor
NOTE! It is very important that you use lubrication oil that corresponds to ambient temperatures (see
lubricating oil chart, page 40). Always change the oil and oil filter according to the service chart.
11
Construction
Oil Pressure Regulating Valve
Oil pressure
The oil pressure regulating valve is located under the oil filter on the left side of the engine. The reg-
ulating valve keeps the oil pressure constant, independent of the engine speed.
At working speed the oil pressure is 2,5 to 5 bar depending on the temperature and the quality of lu-
bricating oil. At idling the pressure is 1,5 bar minimum.
Oil Filter and Oil Cooler
The oil filter is of main flow type. It has a replaceable cartridge mounted on the left side of the engine.
At the bottom of the oil filter cartridge there is a by-pass valve for cold start or possible clogging of
the filter. In addition the engine is equipped with a by-pass centrifugal oil cleaner. The operation is
controlled through a pressure valve in the filter body.
Some engine types are equipped with an oil cooler which is located between the filter frame and the
oil filter. All oil that circulates through the filter also goes through the cooler and is cooled by the en-
gine coolant circulating in the oil cooler.
The 84- and 98-engines are equipped with an plate type oil cooler, that is situated on the right side
of the engine above the filter. The cooler is of main flow type.
Oil Filter and Oil Cooler (84, 98)
1. Oil filter 3
2. Oil pressure regulating valve
3. Oil cooler
4. Coolant drain plug
2
1
12
Construction
COOLING SYSTEM
The coolant pump is attached to the front face of the cylinder block and the thermostat housing is mount-
ed above it.
The system has the internal liquid circulation via the by-pass pipe. The circulation is regulated by the 2-
way thermostat. This arrangement ensures a steady warming-up of the engine under all conditions.
6
1
Cooling System (74 ATI)
1. Coolant pump
2. Thermostats
3. By-pass pipe
4. Radiator
5. Expansion tank
6. Oil cooler
Installing the Engine Heater
Most 4th Generation engines have a coolant pre-heater as standard equipment. It is installed on the left
side of the cylinder block on the same side as the fuel filters (fitting hole ∅ 40 mm). Connecting wires
and mains supply cables are also available in different lengths to help connecting the heater.
Install the coolant pre-heater according to the instructions of the manufacturer.
NOTE! Never use only water as a coolant but a mixture of 40 - 60 % of water and antifreeze (see coolant
quality requirements, page 41).
13
Construction
ELECTRICAL SYSTEM
The electrical system is alternatively 12 or 24 Volts. In the 24 V system some of the electrical equip-
ment in the engine is using 12 Volts via a built-in voltage reducer.
Also the SCR system of the 4th Generation engines operates accordingly at 12 or 24 V nominal volt-
age. NOx sensors are always 12 V and in 24 V systems they are equipped with a voltage reducer. In
order to avoid any damage to the electrical components, do not alter the electrical connections of the
SCR system.
Precautions Concerning the Alternator and Electric Control Units
• Connecting the battery cables to the wrong poles will damage the systems.
• Never open the charging circuit while the engine is running.
• Disconnect the alternator and battery wires before undertaking any electrical welding.
• Disconnect the battery wires before charging the battery.
Starting with an Auxiliary Battery
The following should be noted when using an auxiliary battery to start the engine:
• Check that the auxiliary battery has the same voltage as the standard battery.
• Open the battery plugs to avoid risk of explosion.
• Connect the positive pole (+) of the auxiliary battery to the positive pole of the starter or to the
positive pole of the discharged battery.
• Connect the negative pole (-) of the auxiliary battery for example to the fastening screw of the
starter or to the engine body.
• When the engine starts, first remove the negative cable between the auxiliary battery and the
engine body. Then remove the positive cable.
Never connect the cable to the negative pole of the discharged battery.
Risk of explosion!
14
Construction
SCR SYSTEM
GENERAL
As the emission standards for diesel engines are strictening, AGCO SISU POWER has adopted exhaust
gas treatment with SCR technology (Selective Catalytic Reduction). In SCR technology a liquid called
DEF (Diesel Exhaust Fluid) is injected into exhaust gases. DEF liquids are specified in standards DIN
70070 and ISO 22241. Most commonly known trademarks of DEF are AdBlue, Air1 and Greenox. The
heat of exhaust gases converts DEF to ammonia and carbon dioxide. After this the ammonia reacts with
nitrogen oxides in catalyst reducing them to harmless nitrogen gas and water steam.
The DEF consumption is approximately 6% of the fuel consumption. The DEF tank and pipes are heated
so system works also in low temperatures. If DEF freezes, it is automatically defrosted when the engine
is started. The congealing point of DEF with 32,5 % urea concentration is -11 °C.
See instructions of the appliance for details of filling up, location and capacity of the DEF tank.
The storage of DEF should be done under 30°C, avoiding direct sunlight.
Fuels according to EN 590:2009 may contain up to 7% FAME (fatty acid methyl ester)
type biodiesel according to EN 141214:2008. Fuels according to ASTM D975-09b
may contain up to 5% FAAE (fatty acid alkyl ester) type biodiesel according to ASTM
D6751-08.Contact AGCO SISU POWER R&D for more information of using different
types of biodiesel!
Be aware of using ISO 22241 or DIN 70070 certified urea liquid (DEF, e.g. AdBlue) as
a reducing agent. Diluting of DEF or mixing it with other substances is not allowed,
it may damage the catalyst!
Even small amounts of diesel fuel in DEF tank may damage the gaskets of the SCR
system!
Be careful when handling DEF. DEF is aggressive to some materials and corrosive
to some metals. DEF becomes crystalline when in contact with air. In case of a spill-
age rinse with plenty of water and dry with a clean cloth.
NOTE! The engine meets EU97/68/EC Stage lllB and EPA 40 CFR 89 Tier 4i emission requirements.
Do not fit any components on the engine other than those originally intended for it. The use of other than
original AGCO Sisu Power/SisuDiesel spare parts invalidates the responsibility of AGCO SISU POWER
Inc. on the meeting of the emission requirements.
15
Construction
SCR SYSTEM COMPONENTS AND THEIR FUNCTIONS
The exhaust gas after-treatment system used is Bosch DENOXTRONIC2.2 (DNOX2.2). DNOX2.2
uses SCR (Selective Catalyst Reduction) technology in order to reduce the exhaust emissions from
the engine.
AGCO SISU POWER SCR system consists of EEM4 engine control system and DNOX2.2 SCR sys-
tem. These two systems are connected together via CAN bus.
Supply Module
Supply Module (SM) transfers NOx reductant (DEF) from tank and pressurizes it. It contains also fil-
ters for reductant (prefilter and mainfilter).
Dosing Module
Dosing module (DM) is installed in the exhaust pipe between turbocharger and SCR catalyst. DM
contains an electrically operated, EEM4-controlled solenoid valve, which will inject the required
amount of DEF through the DM nozzle. DEF amount is calculated by EEM4 for optimal reduction of
NOx.
Sensors
DNOX2.2 system includes several sensors:
• NOx sensors
• Exhaust temperature sensors
• DEF tank level sensor
• Temperature sensors: DEF tank, Supply Module internal
16
Construction
SCR SYSTEM TECHNICAL DATA
Principal data
SCR system Bosch DENOXTRONIC 2.2
Minimum operating temperature -40 °C
Maximum DEF temperature 70 °C
Maximum SCR system temperature 80 °C
Dosing system
Reagent fluid type DIN70070/ISO22241 certified DEF (Diesel
Exhaust Fluid), e.g. AdBlue
Injection pressure 9 bars, relative
Dosing quantity 0,15 - 7,2 kg/hr
DEF consumption Approximately 5-7% of fuel consumption*
Pre-filters Bosch 100 µ
Main filter Bosch 10 µ
Cooling system
SCR system cooling type Engine coolant
Cooling flow <400 l/hr
*) DEF consumption may be higher, depending on the application and load profile of the engine.
17
Construction
18
Operation and Driving
OPERATION AND DRIVING

Before using the engine, carefully read the SAFETY INSTRUCTIONS, page 2 and do the inspec-
tions listed in chapter COMMISSIONING THE ENGINE, page 26.
When starting and controlling the engine, follow the instructions made by the manufacturer of the appli-
ance. In the following are some additional points to be considered
1
2
0
DAILY PRE-START CHECK FUEL 1
1
MAX
Before starting the engine, check the following:
MIN
• fuel quantity
• DEF quantity*
• lubrication oil level

MAX.
• coolant level. MIN.
• that the lubrication oil system and coolant system

of the engine are not leaking
• clean the cyclone of the air filter.
*)See instructions of the appliance for information about low

DEF level warning system, indicated by the symbol below.
STARTING
See starting instructions of the appliance.
• Turn the ignition key to position current on. Wait until signal light of intake air heater is off.
• Start the engine and adjust the speed with the speed lever to prevent the engine from racing.
• Watch the oil pressure. To ensure sufficient lubrication, the pressure gauge has to be within normal
range in 3 - 4 seconds after starting. This is particularly important for the lubrication of the turbo-
charger.
• A cold engine might have, for a short period, an oil pressure of even 7 - 9 bar, depending on oil
quality and temperature.
• Always accelerate the engine at an even rate, never by racing.
NOTE! If the engine has not been used for over a month, dismount the pressure oil pipe of the turbo-
charger and pour clean lubrication oil (abt. 0,1 ltr) into the bearing housing of the turbocharger.
NOTE! Ensure that the SCR system is able to start after standing unused for long time (over 6 months)
by performing a normal afterrun procedure and keeping the system closed, also the fuel tank ventilation,
if possible. Any other procedure (drying with compressed air, flushing) could damage the SCR system
and has to be avoided.
19
When re-starting, it is recommended to change the Diesel Exhaust Fluid (DEF) because of aging ef-
fects (condensed water could change the concentration of the DEF and thus affect the emissions. It
is recommended to change the main filter element (see page 35) before starting the engine.
COLD START
Always use, if possible, the coolant heater when the temperature is below 0°C
See starting instructions of the appliance.
See also actions before winter, page 39.
Engine is equipped with an electric pre / post

heater of the intake air. The post heating
operates automatically. 0°C
The DEF tank and pipes are heated so the SCR
system works also at low temperatures. If DEF
freezes, it is defrosted when the engine is started.
The congealing point of DEF is -11°C.
Never use starting aerosol to start the engine! The intake air heater causes an ex-
plosion in the intake manifold. This can result in serious damage to the engine
and personal injuries. Use of starting aerosol invalidates the engine warranty.
• Make sure the battery is sufficiently charged.

• Release the engine of all extra load (move the gear to neutral position, depress the clutch
pedal, do not turn the steering wheel etc.).
• Keep the gas pedal on idling position. Heat the time when the alarm light is on and start the
engine. If the engine doesn’t start during ten seconds, stop the starting and heat again. (The
preheating of intake air doesn’t work during the starting.) When the engine starts, you can sup-
port it with the starter until the engine runs complete.
• Watch the oil pressure.
• Do not race the cold engine because the lubrication is not sufficient while the oil is cold.
Warming up the engine
Since the engine wear is greatest when the engine is running cold, warm up the engine quickly with
a light load for a couple of minutes after starting. However, you must not load the engine heavily and
the rotation speed must not exceed 2000 rpm when the engine temperature is below 50°C.
20
ATTENTION DURING OPERATION

See instructions of the appliance.
The fuel system is equipped with a pressure sensor that alarms before interference has developed. Rea-
sons can be for instance:
• Empty fuel tank.
• Clogging fuel filters.
• Suction piping clogged or leaking air.
• Unsuitable fuel (e.g. summer fuel in the winter).
NOTE! The automatic protection in the EEM4 unit on the engine limits the engine power or forces to stop
the engine as a consequence of certain defect codes. Observe the fault code display or -light and act
accordingly, see table on page 44.
2,5 - 5 bar
• Check the engine oil pressure
- running speed 2,5...5 bar
3
- idling speed min. 1,5 bar 2 4
5
1
bar
• Check the coolant temperature
- normal running temp. 75...95°C 75 - 95°C
100
40 120
• Watch the ammeter reading/warning light
NOTE! If the engine is overheated, cool it slowly down by idling for a few minutes. Never pour cold cool-
ant into hot engine! Never remove the 2-way thermostat to reduce the temperature. In that case a greater
quantity of the coolant is circulating via the by-pass pipe and the temperature is getting higher than be-
fore.
It is dangerous to open the cap of the pressurised hot radiator!
NOTE! Avoid long periods of idling because then the temperature of combustion is reduced. This causes
incomplete combustion and carbon formation which may seize the nozzles and clog the valves and pis-
ton rings.
Eventual running troubles, see chart in page 43.
21
STOPPING
See stopping instructions of the appliance.
NOTE! Never stop a turbocharged engine immediately after heavy driving. Let it idle for a few minutes
to equalize the temperatures.
• Disconnect the current from the main switch if the engine is not at once again started.
• Do not cut off the current for alternator and electronic control unit as engine is running.
NOTE! If the EEM4 self- diagnostics has shut the engine off, it can be re-started by turning the current
off and then starting again. If the cause of the stopping is not eliminated, the self-diagnostics shuts
the engine off again or does not allow it to start.
22
COUPLING ADDITIONAL EQUIPMENT TO THE ENGINE

Power for different accessories can be taken out from the engine crankshaft or a separate power take-
off. Ensure that no continuous axial powers are caused to the crankshaft or power take-off by the acces-
sories.
NOTE! After assembling the clutch or the gear check the axial play of the crankshaft, which should be
0,10...0,35 mm.
Hydraulic pump PTO with

direct drive
Hydraulic pump PTO with

drive device
23
24
Service
SERVICE
PERIODICAL MAINTENANCE
One of the most essential preconditions for secure operation of your engine is proper maintenance at
regular intervals. Maintenance costs are low compared to costs caused by negligence.
Maintenance Work
Always stop the engine before service.
Clean the engine and its surroundings before you start service work.
SERVICE CHART
MAINTENANCE WORK SERVICE INTERVAL/

RUNNING HOURS
10 100 500* 1000 4000
1. Check engine oil level X1
2. Check coolant level X1
3. Check for oil, fuel or coolant leakages X1
4. Clean air filter cyclone X1
5. Clean/change air filter X

6. Clean cooling system (from outside) X
7. Check fan belt tightness X
8. Check battery fluid level X
9. Change engine oil and oil filter X3
10. Change fuel filters X2

11. Drain water out of fuel tank X3
12. Adjust valves X4
13. Turbocharger and intercooler inspection in an X

authorised workshop
14. Change SCR supply module main filter ONCE A YEAR5

15. Change coolant EVERY TWO YEARS
1
) or once a day.
2
) or earlier according to engine control system notified by specific service code.
3
) or once a year (in the autumn).
4
) adjust the valve clearances first time after 500 running hours and after that after every 1000 running
hours.
5
) or after 1200 running hours.
*)Oil change intervals depend on engine type and application, see page 29.
25
Service
COMMISSIONING THE ENGINE

Do the following inspections before starting up the engine.
• Engine oil level

• Radiator coolant level
• Battery fluid level and charge
• Coupling of additional equipment
• Crankshaft end play
• Idling speed
• Max. running speed
• Oil pressure / charging
• Thermometer operation
• Operation of EEM 4 self-diagnostics
SERVICES TO BE MADE DAILY OR AT 10 HOURS INTERVALS
1. Check Engine Oil Level
Stop the engine and wait for a few minutes before checking. The oil level should be between the max.
and min. lines on the dipstick. When adding oil, top up to the max. line.
MAX
MIN
NOTE! Overfill will cause excessive oil splash in crankcase resulting in increase oil consumption.
2. Check Coolant Level
Open the radiator cap carefully. If the coolant is hot, there is an overpressure in
the system.
The coolant level should be slightly above the radiator core.
The coolant level should be between the MAX and MIN lines if the system is provided with an expan-
sion tank.
Check the freezing point of the coolant before the cold season.
NOTE! Never use only water as coolant!
NOTE! The hot engine can be damaged if you pour cold coolant into it!
26
Service
3. Check for Leakages (Fuel, Oil, Coolant)
Find any leakage points and eliminate them as soon as possible. The coolant pump is
provided with a telltale hole on the left side. This hole must not be blocked. If coolant
drops out of the hole, the coolant pump must immediately be repaired. There may be
a slight leakage on a new pump before it has been run in.
4. Clean Air Filter Cyclone
Always stop the engine before cleaning. Undo the locking

clamp or the nut on the cyclone, empty and clean the glass
bowl. Refit the glass bowl. MAX
SERVICES TO BE MADE WEEKLY OR AT 100 HOURS INTERVALS
5. Clean / Change Air Filter
See also instructions of the appliance.
Always stop the engine before cleaning / changing.
Unscrew the nut at the end of the air cleaner or undo the
locking clamps and take out the filter element.
If the air filter is equipped with a safety filter element do not

take it out but change it at 1500 h intervals.
Clean the filter element with compressed air with a max.

pressure of 5 bar which should be directed obliquely from
the middle of the filter and outwards.
Hold the filter against the light, or lower an electric light

down through the filter and check that there are no holes
or cracks. If faulty, the filter element must be changed.
When you fit the filter element, check that it is properly lo-
cated, the seals are in good condition and the sealing sur-
faces are clean. Do not tighten the nut at the end of the air
cleaner too hard.
Engine Warranty is valid only when Original AGCO Sisu Power/SisuDiesel Air Filter elements are
used.
27
Service
6. Clean Cooling System (from outside)
Check and clean the outside of the radiator from time to time. Use compressed air or water spray to
remove dirt and impurities. Avoid too high a pressure. The direction of the air or water spray must be
against normal air flow.
7. Check Fan Belt Tightness
The engine is equipped with a spring loaded belt ten-

sioner and the belt is of V-ribbed type. The tensioner
tightens the belt automatically during the operation.
Check the belt visually. Change a worn, oily or dam-

aged belt.
Belt Replacing
Before removing the old belt check its routing to make

sure that the new belt is fitted the same way.
Turn the tensioner against the direction of tightening

until the belt is loosened. Loosen belts of possible ac-
cessories (e.g. compressor).
- using a 3/8 in square drive inserted into the square
hole in the tensioner (arrowed).
- pay attention to free rotation of tensioner roller and
also the right tightness of fixing screw 48 Nm.
- fit the new belt and other loosened parts.
Some 84 and 98 engines have coolant pump driven by

Flexonic belt. The Flexonic belt does not have a sepa-
rate tensioner. Belt replacing is recommended after
every 3000 running hours or when it has been re-
moved.
Fit a new Flexonic belt with fitting tool 9201 86480 or a fit-
ting device delivered with the replacement belt.
Make sure that the engine cannot be started during belt replacing. Disconnect the
battery before doing this job.
8. Check Battery Fluid Level
The fluid should stand abt. 5...10 mm above the cell plates in the battery.
Top up with distilled water if required. During the cold season it is important that the engine is allowed
to run for a while after topping up with distilled water. This is to avoid the freezing of the water before
it has had time to mix with the battery acid.
Keep the battery clean and dry on the outside. Ensure proper mounting of the battery.
Clean and protect the pole studs and the cable terminals with battery grease.
Never use an open flame near the battery to check the fluid level.
28
Service
SERVICES TO BE MADE AT 500* HOURS INTERVALS

9. Change Engine Oil and Oil Filter
* Oil change intervals depend on engine type and application:
33, 44, 49, 66 and 74 engines 500 hours,
84 and 98 engines 400 hours, min. 6,0 max. 7,5 dm 3

33
84 and 98 combine engines 250 hours.

3
See also instructions of the appliance. min. 8,0 max. 10,0 dm
Run the engine until it is warm. Stop the engine. Remove

the draining plug and drain the oil into a suitable container. min. 9,5 max. 11,5 dm 3
When the oil sump is empty, refit the plug. 44

49
Take old oil to a proper disposal point.
3
min. 25,5 max. 29,0 dm
The engine may be equipped with an oil draining pump

(e.g. marine engines), in that case use the pump to drain
the oil.
3
Fill new oil to the prescribed level (upper mark line on dip- min. 26,0 max. 30,5 dm
stick) through the filler hole. Note the capacity of the oil fil-
ter.
3
1 dm3 = 1 litres min. 21,5 max. 25,5 dm
98-engine:
Oil sump capacity: min. 28,0 - max. 35,0 dm3 3

min. 42,0 max. 46,5 dm
Regarding oil grade, see Lubrication Oil Chart, page 40.
Change Oil Filter
Before removing the oil filter clean the surroundings of it. Use the loop tool to unscrew the old filter. Lu-
bricate slightly the rubber gasket of the new filter and clean the sealing faces. Tighten the new filter by
hand. Wipe off any oil run onto the chassis. Start the engine. Do not race. Ensure that no oil is leaking
from the filter. Take the old filter to a proper disposal point.
Engine warranty is valid only when original AGCO Sisu Power/SisuDiesel oil filters are used.
The Breather Pipe
Always check that the breather pipe is clean and unclogged at the same time as changing the oil.
29
Service
SERVICES TO BE MADE AT 1000 HOURS INTERVALS

10. Change Fuel Filters
Absolute cleanliness is required when servicing fuel system.

• Clean the filters and surrounding area.
• Disconnect the pre-filter water detector connector.
• Turn the pre-filter element anticlockwise and

remove the element from its mounting bracket.
Collect the fuel into a suitable container. Detach
the water detector from the pre-filter bottom end.
• The main filter is removed in a similar way.
• Attach the water detector to the new pre-filter bot-

tom end.
• Lubricate the filter element o-ring seal with clean

fuel
• Fill the outer shell of the filter element with clean

fuel.
• Turn the filter element to its mounting bracket,

tightening torque 40 Nm.
• Connect the water detector connector.
• The main filter is assembled in a similar way
• Bleed the fuel system as described below.
• Start the engine and check the fuel system tight-

ness.
Take the old filter elements to a proper disposal

point.
Engine warranty is valid only when original

AGCO Sisu Power/SisuDiesel fuel filter elements
are used.
Bleeding the fuel system
• Open the bleeding plug on the pre-filter bracket.
• Put a transparent hose in the plug hole and lead it

into a suitable container
• Pump fuel with the hand pump on top of the pre-fil-

ter bracket.
• Pump with the hand pump until there are no air

bubbles in the fuel stream.
• Remove the hose and turn back the bleeding plug.
• Clean the engine of eventual overspill fuel.
• Start the engine. The fuel system removes auto-

matically the air left in the system.
30
Service
NOTE! The fuel system is equipped with a pressure sensor that alarms before interference
has developed. Reasons can be for instance:
• Empty fuel tank.

• Clogged fuel filters.
• Suction piping clogged or leaking air.
• Unsuitable fuel (e.g. summer fuel in the winter).
NOTE! Use of spirits as antifreeze is not useful or recommended at all. It makes the fuel solidify and
weakens the lubricating qualities of the fuel and increases the possibility of corrosion.
11. Drain Fuel Tank
The fuel tank should be cleaned before the winter. Thus you avoid troubles caused by the water in the
fuel system. The best way to prevent condensation is to always keep the fuel tank as full as possible.
• Empty the fuel tank and rinse it with pure fuel.

• Fill the fuel tank with fuel for winter conditions. The
fuel must be according to norm EN 590, see page
41.
31
Service
12. Adjust Valve Clearances
NOTE! Adjust the valve clearances first time after 500 running hours and after that after every
1000 running hours.
The nominal clearance of both inlet and exhaust valves is 0,35 mm. The valve clearances can
be checked regardless of whether the engine is cold or hot. The valve clearances of a certain
cylinder can be adjusted when the piston is at its compression stroke top dead centre.
33-engine
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).
44/49-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 cyl-
inder 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
66/74/84-engines
• Rotate the crankshaft by 1/3 of a turn in the running direction so that valves in the 2nd cyl-
inder are rocking. Check valves in the 5th cylinder.
Injection order 1-5-3-6-2-4

Valves rock in cyl. no. 6-2-4-1-5-3
98-engine
• Rotate the crankshaft in the running direction so that valves in the 7th cylinder are rocking.
Check valves in the 2nd cylinder.
Injection order 1-2-4-6-7-5-3

Valves rock in cyl. no. 6-7-5-3-1-2-4
32
Service
1. Exhaust valve
2.Inlet valve
3. Injector
Adjustment
The adjustment has to be made from the space between the rocker and the connecting cap as shown
in the picture.
• Loosen the locknut on the adjusting screw.

• Check the clearance with a feeler gauge and
adjust to the correct clearance by turning the
adjusting screw.
• Tighten the locknut and check again that the
clearance is correct.
33
Service
SERVICES TO BE MADE AT 4000 HOURS INTERVALS

13. Check Turbocharger Play and Check that the Intercooler Cell is Clean
The turbocharger and the intercooler cell service must be entrusted to an expert technician at AGCO
Sisu Power Service.
It is essential to carry out regular engine services to keep the turbocharger in good condition. Special
attention must be paid to the cleanliness of the air filter cartridge and to the engine oil and oil filter
change at recommended intervals. Check regularly that the turbocharger is properly fitted to the ex-
haust manifold as well as the tightness of the inlet and exhaust manifold joints. Correct adjustment
of the injection equipment is essential for the operation of the turbocharger.
When a new turbocharger is installed, pour abt. 0,1 ltr of pure engine oil into the bearing housing
before attaching the pressure oil pipe. Ensure that no impurities are entering the turbocharger with
the oil.
34
Service
SERVICES TO BE MADE ONCE A YEAR

SCR System Maintenance
AGCO SISU POWER SCR system is durable and almost maintenance free. Only main filter change for
supply module is required in normal use. AGCO SISU POWER SCR is equipped with on-board diagnos-
tic, which will warn the operator or limit the usage of the machine if any problems (e.g. leakages or block-
ing of lines) occur in the system.
Fuels according to EN 590:2009 may contain up to 7% FAME (fatty acid methyl ester)
type biodiesel according to EN 141214:2008. Fuels according to ASTM D975-09b
may contain up to 5% FAAE (fatty acid alkyl ester) type biodiesel according to ASTM
D6751-08.Contact AGCO SISU POWER R&D for more information of using different
types of biodiesel!
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used. Diluting of
DEF and mixing it with other substances is not allowed, it may damage the catalyst!
Even small amounts of diesel fuel in DEF tank may damage the gaskets of supply
module and dosing module.
14. Change SCR system main filter
The main filter is located under the filter cover in the supply module of DNOX2.2-system. No special tools
are needed for filter change.
Main filter change
• Turn the filter cover anti-clockwise with a 27mm spanner and remove the cover.
• Pull out the equalizing element.
• Pull out the filter element with small pliers.
• Insert new filter element and equalizing element.
• Install the filter cover back; tighten to 22,5 +/- 2,5 Nm with a 27 mm spanner.
All the sealing surfaces on the filter cover, equalizing element, filter element and
supply module housing must be absolutely clean and undamaged!
NOTE! It must be checked if there are cracks around the area of the filter cover. No cracks in the material
are allowed. If there are cracks in the housing the entire supply module must be replaced! If there are
cracks in the filter cover the filter cover must be replaced.
Take the old equalizing element and filter element to a proper disposal point.
35
Service
Do not install used and/or wet filter or equalizing element, danger of damage and
poor filtration.
Do not use mineral or silicone oils or greases when assembling the filter seals!
All seals have teflon coating.
36
Service
SERVICES TO BE MADE EVERY TWO YEARS
15. Change Coolant
Change the coolant every two years. This ensures that the anti-corrosive is always active. See page 41
for the quality requirements of the coolant.
At the same time check the tightness and condition of rubber hoses of the cooling system. Renew broken
or damaged hoses before filling the system.
Draining the Cooling System
1. Drain plug on radiator

2. Drain plug on cylinder block
3. Drain plug on oil cooler
4. Bleed plug
Drain Cooling System
• Remove the filler cap.

• Remove the draining plugs on the radiator and on the left side of the cylinder block.
• Remove also the draining plugs on the oil cooler (on the left side of the engine on 33-, 44-, 49-, 66-
and 74-engines, on the right side on 84- and 98-engines).
• Make sure all coolant is drained out and no impurities are blocking the draining hole.
• The engine assembly may also have other draining plugs (e.g. on the engine heater
piping). Remove also these plugs when you change the coolant.
Fill Cooling System
• Fill the cooling system with a mixture of antifreeze and coolant until the coolant level comes
above the radiator core.
• Bleed the cooling system by removing the air venting plug/temperature sensor on the
thermostat housing.
• Pour coolant until the coolant level reaches the plug. Screw in the plug and fill rest of the system
NOTE! Never use only water as coolant
37
Service
38
Additional Service Instructions
ADDITIONAL SERVICE INSTRUCTIONS
BLEEDING THE FUEL SYSTEM

After changing the fuel filters or if the engine has ran out of
fuel the fuel system has to be bleeded.
• Open the bleeding plug on the pre-filter bracket.
• Put a transparent hose in the plug hole and lead it

into a suitable container
• Pump fuel with the hand pump on top of the pre-fil-

ter bracket.
• Pump with the hand pump until there are no air

bubbles in the fuel stream.
• Remove the hose and turn back the bleeding plug.
• Clean the engine of eventual overspill fuel.
• Start the engine. The fuel system removes auto-

matically the air left in the system.
Do not open high pressure pipe connectors of the fuel system when the engine is
running. Wait at least 30 sec. after stopping the engine. If the jet of high pressure fuel
contacts your skin, fuel penetrates the skin causing severe injuries. Get medical help
immediately!
BEFORE THE COLD SEASON

• Drain the fuel tank of water.
• Replace the fuel filter and pre-filter.
• Ensure that the fuel in the tank is of winter quality.
• Change the engine oil (winter quality).
• Check the battery condition.
• Check the function of the intake air heater.
• Check the function of the coolant pre-heater.
TIGHTENING TORQUES
Object Nm
Cylinder head bolts and nuts.......................................................................................80 Nm + 90° + 90°
Main bearing screws ...........................................................................................................200
Connecting rod screws M12......................................................................................40 Nm + 80 Nm + 90°
Connecting rod screws M14 (84/98)...........................................................................80 Nm + 180°
Crankshaft nut, 33/44/49......................................................................................................600
Crankshaft nut, 66/74/84/98...............................................................................................1000
Crankshaft pulley screws ......................................................................................................30
Crankshaft pulley screws, 74/84/98 .......................................................................................80
Flywheel screws ..................................................................................................................150
Flywheel screws, 84/98........................................................................................................200
39
Flywheel housing screws:

- M12 ................................................................................................................................... 150
- M10 ..................................................................................................................................... 80
Idler gear screws, 33/44/49/66:
- M10...................................................................................................................................... 60
- M14.................................................................................................................................... 200
Idler gear screws (with ball bearing), 66/74/84/98:
- M14 ................................................................................................................................... 180
- M8 ....................................................................................................................................... 32
Piston cooling valve .............................................................................................................. 30
Oil pump retaining screws .................................................................................................... 60
Oil cooler connecting piece ................................................................................................... 60
Coolant pump pulley screw, 33/44/49 ................................................................................... 80
Coolant pump pulley nut, 33/44/49/66/74 ............................................................................ 120
Coolant pump gear nut, 84/98 ............................................................................................. 180
Belt tightener screw ............................................................................................................... 48
Exhaust manifold screws ...................................................................................................... 50
Injector retaining screw.......................................................................................................... 40
Injector wire nuts (M4) .......................................................................................................... 1,5
High pressure pump gear nut ................................................................................................ 80
Fuel filter elements ................................................................................................................ 40
Pre-filter water detector ........................................................................................................... 6
LUBRICATING OIL QUALITY REQUIREMENTS

Use lubricating oils fulfilling following quality grades.
API -grade ACEA -grade

CJ-4 E9 °C
+40
Select viscosity grade from table beside +30

corresponding to outside temperature.
+20
Oil capacities, see page 29. SAE 30
+10
SAE 20W-20
SAE 20W-40
SAE 15W-40
0
SAE 10W-40
SAE 10W-30
-10
SAE 5W-30
SAE 5W-40
-20
-30
-40
Lubricating oil is hazardous to health. Avoid prolonged contact with the skin.
The oil mist is dangerous to inhale.
40
COOLANT QUALITY REQUIREMENTS

The coolant used must meet the demands of standard ASTM D 3306 or BS 6580:1992.
• The cooling mixture must consist 40...60 % of eth-

ylene/propylene-glycol based antifreeze and
water. The best proportion is 50 % of antifreeze
liquid and 50 % of water.
• The water used must be mechanically clean and
not too acid (e.g. swamp water) or too hard (calcif-
erous well water).
• Check periodically the proportion (the frostproof)
of the coolant. Change the coolant every two
years.
NOTE! Never use only water as coolant!
Antifreeze is hazardous to health. Avoid contact with the eyes and skin.
FUEL QUALITY REQUIREMENTS
Requirement Test method

Density, +15°C 0,82...0,84 kg/dm3 EN ISO 3675:1998, EN ISO 12185
Viscosity, +40°C 2,0...4,5 mm2/s EN ISO 3104
Sulphur content max. 15 mg/kg EN ISO 14596:1998
Cetane number min. 51 EN ISO 5165:1998
Water content max. 200 mg/kg prEN ISO 12937:1996
lubricity/HFRR max. 460 µm ISO 12156-1
The fuel must be according to norm EN 590:2009 or ASTM D 975-09b 1-D or 2-D.
Supplementary admixtures or additives are not allowed.
Be aware of using DIN 70070/ISO 22241 certified DEF (AdBlue) as a reducing agent.
If urea quality sensor detects a problem related to urea quality, it will alert the engine
control system via CAN message thus causing the engine to run under degraded
mode.
The storage of DEF should be done under 30°C, avoiding direct sunlight.
Engine output depending on fuel quality
Different fuel qualities like temperature, density and viscosity affect the actual output of the engine. Our
outputs are specified by fuel with a density of 0.84 kg/dm3 and specific heat rate of 42,7 Mj/kg at a fuel
temperature of +15°C.
The correction in % caused by the change of fuel qualities is seen in the attached figures.
41
OUTPUT %
+5
A
FIG. A. Engine output dependence on fuel temperature.

+35°C is the reference temp (correction 0%). The fuel temper- 0
ature is not only a function of ambient conditions but also var-
ies according to the fuel system of the application (tank size
and location, return flow etc.).
-5
35
10 20 30 40 50 60
FUEL TEMPERATURE °C
OUTPUT %
+5
B
FIG. B. Engine output dependence on fuel density. Normal
value is 0,84 kg/dm3 at +15°C.
0
-5
0,84
0,80 0,85 0,90
DENSITY kg/dm 3
OUTPUT %
+5
FIG. C. Engine output dependence on fuel viscosity. Normal C
value is 3 cSt at +20°C.
-2
Note fig. B and C only if the fuel quality is changed. 2 3 4 5 6 7 8
VISCOSITY cSt
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.
Alternative Fuels
Using diesel fuel according to European norm EN 590:2009 or ASTM D 975-09b 1-D or 2-D, all
AGCO Sisu Power engines have full warranty for the specified warranty period and the engines will
work well with good reliability and long life time.
NOTE! Use of fuel not meeting these requirements may result as reduced performance and shorter
engine life. It also invalidates he engine warranty.
Fuels according to EN 590:2009 may contain up to 7% FAME (fatty acid methyl

ester) type biodiesel according to EN 141214:2008. Fuels according to ASTM
D975-09b may contain up to 5% FAAE (fatty acid alkyl ester) type biodiesel ac-
cording to ASTM D6751-08.Contact AGCO SISU POWER R&D for more informa-
tion of using different types of biodiesel!
42
EEM4 ENGINE CONTROL SYSTEM FAULT CODES

(See also manual of the appliance.)
When the control system uses the CAN bus, you can read- / write out from the display in cabin, all the
filed or active fault reports in the system.
The EEM4 self-diagnostics monitors different functions in the engine giving a fault report in case of pos-
sible disturbance. Additionally in certain cases, it limits the engine power, performing a so called delayed
stopping or a so called forced stopping. The code in the display tells the cause as described on the last
pages table. Some functions are optional.
NOTE! If the engine stops or the power decreases without any code in the display, the cause might be
a fault outside the supervision of the control system, momentary overload or a mechanical damage, see
page 54.
If the self-diagnostics has stopped the engine, it can be started again by disconnecting the current and
starting again. If the cause of the stopping is not eliminated, the self-diagnostics stops the engine again
or does not allow it to start.
NOTE! The EEM4 engine control system can only be ruled by EEM4 service tool. The EEM4 system
service must be entrusted to an expert at AGCO Sisu Power/SisuDiesel service.
43
The EEM4 Fault Codes for SW version e401-1.0.4-a

(see explanations in the end for the abbreviations)
Degra Shut
SPN FMI FAULT DESCRIPTION
dation down
110 4 1 Coolant temp sensor voltage below normal
COOLANT 110 3 1 Coolant temp sensor voltage above normal or open circuit
TEMPERATURE
110 16 FLm Coolant temperature ABOVE NORMAL (>106C)
110 0 FLm Coolant temperature HIGH, ALARM (>113C)
174 4 1 Fuel temp sensor voltage below normal
FUEL 174 3 1 Fuel temp sensor voltage above normal or open circuit
TEMPERATURE 174 16 FLm Fuel inlet temperature HIGH, ALARM (>85C)
105 4 1 Intake air temp sensor voltage below normal
INTAKE AIR 105 3 1 IIntake air temp sensor voltage above normal or open circuit
TEMPERATURE 105 16 1 Intake air temp ABOVE NORMAL (>90C)
100 4 1 Oil pressure sensor voltage below normal
100 3 1 Oil pressure sensor voltage above normal or open circuit
OIL PRESSURE 100 16 2 Oil pressure ABOVE NORMAL (9,5 bar/30°C)
100 18 Oil pressure LOW
100 1 X Oil pressure LOW, ALARM
102 4 1 Boost pressure sensor voltage below normal
BOOST 102 3 1 Boost pressure sensor voltage avove or open circuit
PRESSURE 102 18 3 Boost pressure LOW
102 31 Intake manifold pressure drop too HIGH at cranking
157 4 3 Rail pressure sensor voltage below normal
157 3 3 Rail pressure sensor voltage above normal or open circuit
157 16 3 Rail pressure raw value is intermittent
RAIL PRESSURE
157 2 Rail pressure raw value is above maximum offset
157 20 Rail pressure raw value is below minimum offset
157 16 3 Rail pressure ABOVE NORMAL
POWERSTAGE 520200 16 Powerstages could be disabled due to high battery voltage
DIAGNOSIS 520200 18 Powerstages could be disabled due to low battery voltage
CRANKSHAFT 4201 2 2 Crank speed signal erratic, too much noise pulses
SENSOR 4201 31 2 Crankshaft speed sensor signal missing
9080 31 2 Signal deviation between crankshaft and camshaft too large
CAM SPEED 9081 31 2 Cam speed sensor signal missing
SENSOR 9082 31 2 Number and/or position of the camshaft pulses implausible - disturbed sig-
nal
WATER IN FUEL 97 31 2 Water in fuel
DETECTOR
94 4 1 Fuel main filter inlet pressure sensor voltage below normal
94 3 1 Fuel main filter inlet pressure sensor voltage above normal or open circuit
FUEL FILTER
94 16 1 Fuel main filter inlet pressure ABOVE NORMAL
PRESSURE
94 18 1 Fuel main filter inlet pressure BELOW NORMAL
94 31 3 Fuel main filter inlet pressure ALARM, out of safe operating range
1136 3 ECU temperature sensor voltage above normal or open circuit
ECU 1136 4 ECU temperature sensor voltage below normal
TEMPERATURE
1136 0 X ECU over temperature HIGH, ALARM
AMBIENT 108 4 Ambient pressure sensor voltage below normal
PRESSURE 108 3 Ambient pressure sensor voltage above normal or open circuit
171 4 Ambient temperature sensor voltage below normal
AMBIENT 171 3 Ambient temperature sensor voltage above normal or open circuit
TEMPERATURE
171 19 Ambient temperature CAN signal missing
639 19 Bus off Vehicle CAN (250k)
CAN BUS 520201 19 Bus off Engine CAN (1M)
3509 31 5Vdc Supply 1 voltage out of range
5VdcREFERENCE 3510 31 5Vdc Supply 2 voltage out of range
SUPPLIES
3511 31 5Vdc Supply 3 voltage out of range
3512 3 12V sensor supply 1 voltage above normal
12v SUPPLY 3512 4 12V sensor supply 1 voltage below normal
44
Degra Shut
dation down
1043 3 internal 12V supply voltage above normal
12v SUPPLY 1043 4 internal 12V supply voltage below normal
1485 31 Main relay early opening at previous afterrun
MAIN RELAY 1485 11 ECU internal power off ERROR at previous afterrun
MAIN RELAY 520202 4 ECU Main Relay1 short circuit to GROUND
SHORT CIRCUIT 520203 4 ECU Main Relay2 short circuit to GROUND
TO GROUND
MAIN RELAY 520202 3 ECU Main Relay1 Short circuit to HIGH SOURCE
SHORT CIRCUIT 520203 3 ECU Main Relay2 Short circuit to HIGH SOURCE
TO BATTERY
AIR FILTER 107 18 Air filter pressure BELOW NORMAL
PRESSURE 107 31 Air filter pressure sensor active at init state
MONITORING
168 3 Battery voltage sensor voltage above normal
BATTERY 168 4 Battery voltage sensor voltage below normal
VOLTAGE
168 0 Battery voltage ABOVE NORMAL(>17V(12V)) (>32V(24V))
168 1 Battery voltage BELOW NORMAL (<7.8V)
91 4 Throttle 1 sensor below normal (IDLE)
THROTTLE 1 91 3 Throttle 1 sensor above normal or open circuit (IDLE)
157 17 3 Rail pressure controller, Negative deviation
157 15 3 Rail pressure controller, Positive deviation
RAIL PRESSURE
157 31 3 Rail pressure, Leakage detected by quantity balance
MONITORING
157 18 3 Rail pressure below normal
157 0 3 X Rail pressure above normal
520408 31 3 Rail PRV recognised as OPEN
520243 31 3 Rail PRV is forced to open; perform pressure increase
PRESSURE
520244 31 3 Rail PRV is forced to open; perform pressure shock
RELIEF VALVE
520245 31 3 Rail PRV reached maximum allowed opening count
520246 31 3 Rail PRV reached maximum allowed open time
729 3 Grid heater voltage above normal
GRID HEATER 729 4 Grid heater voltage below normal
1076 6 MPROP control, High side short circuit to GROUND
1076 4 MPROP control, Low side short circuit to GROUND
1076 3 MPROP control, High side short circuit to HIGH SOURCE
MPROP 1076 5 MPROP control, Low side short circuit to HIGH SOURCE
1076 14 MPROP control, Open circuit
1077 31 MPROP control, Powerstage over temperature
1077 3 MPROP control, Metering unit AD-channel voltage above normal
1077 4 MPROP control, Metering unit AD-channel voltage below normal
651 6 3 Solenoid valve 1, Current above normal: Short circuit between cables
SOLENOID 651 5 3 Solenoid valve 1, Current below normal: Open circuit
VALVE 1
651 14 3 Solenoid valve 1, Short circuit
VALVE 2
VALVE 3
VALVE 4
VALVE 5
45
Degra Shut
dation down
VALVE 6 656 14 3 Solenoid valve 6, Short circuit
3 14 Number of injections is limited by quantity balance of high pressure pump
520209 31 2 Error in the plausibility of the injection energizing time
INJECTORS 520210 12 Error in the plausibility of the start of energising angles
520240 31 Injector bank 0 short circuit
520241 31 Injector bank 1 short circuit
CY33X 520211 31 Chip error in the CY33x power stage component
520212 31 Diagnostic fault check to report the NTP error in ADC monitoring
520213 31 Diagnostic fault check to report the ADC test error
520214 31 Diagnostic fault check to report the error in Voltage ratio in ADC monitoring
520215 31 Diagnostic fault check to report errors in query-/response-communication
520216 31 Diagnostic fault check to report errors in SPI-communication
520217 31 Diagnostic fault check to report multiple error while checking the complete
MOCSOP ROM-memory
(test of redun- 520218 31 Loss of synchronization sending bytes to the MM from CPU
dant shut-off 520219 31 DFC to set a torque limitation once an error is detected before MoCSOP's
paths)
error reaction is set
520220 31 Wrong set response time
520221 31 Too many SPI errors during MoCSOP execution
520222 31 Diagnostic fault check to report the error in undervoltage monitoring
520223 31 Diagnostic fault check to report that WDA is not working correct
520224 31 OS timeout in the shut off path test. Failure setting the alarm task period
520225 31 Diagnostic fault check to report that the positive test failed
520226 31 Diagnostic fault check to report the timeout in the shut off path test
520227 31 Diagnostic fault check to report the error in overvoltage monitoring
CY320 520228 12 Cy320 Multiple Power Supply module SPI/COM-Error
CATALYST OUT- 4363 3 SCR catalyst outlet gas temp sensor voltage above normal or open circuit
LET TEMPERA- 4363 4 SCR catalyst outlet gas temp sensor voltage below normal
TURE SENSOR
CATALYST INLET 4360 3 SCR catalyst inlet gas temp sensor voltage above normal or open circuit
TEMPERATURE 4360 4 SCR catalyst inlet gas temp sensor voltage below normal
SENSOR
3031 3 DEF tank temperature sensor voltage above normal or open circuit
DEF TANK 3031 4 DEF tank temperature sensor voltage below normal
TEMPERATURE
3031 14 DEF tank maximum defrost time exceeded
SENSOR
3031 10 DEF tank temperature abnormal rate of change at heating cycle
3031 18 DEF tank temperature ABOVE normal
1761 3 DEF tank level sensor voltage above normal or open circuit
1761 4 DEF tank level sensor voltage below normal
DEF TANK LEVEL
1761 1 DEF tank EMPTY
1761 18 DEF tank LEVEL LOW
4375 5 DEF pump motor control signal current below normal or open circuit
4375 31 DEF pump motor control powerstage over temperature
4375 3 DEF pump motor control signal short circuit to HIGH SOURCE
DEF PUMP
MOTOR 4375 4 DEF pump motor control signal short circuit to GROUND
4374 8 DEF pump motor speed deviation
4374 14 DEF pump motor speed permanent deviation
4374 31 DEF pump motor not available for actuation
DEF PRESSURE 4334 3 DEF pressure sensor voltage above normal or open circuit
SENSOR 4334 4 DEF pressure sensor voltage below normal
DEF PUMP 521000 8 DEF pump temperature signal duty cycle in failure range
TEMPERATURE 521000 2 DEF pump temperature signal duty cycle in invalid range
46
Degra Shut
dation down
4376 5 DEF pump direction valve low side current below normal or open circuit
4376 3 DEF pump direction valve low side short circuit to HIGH SOURCE
4376 4 DEF pump direction valve low side short circuit to GROUND
DEF PUMP
4376 31 DEF pump direction valve low side control powerstage over temperature
DIRECTION
VALVE 521002 31 DEF pump direction valve high side control powerstage over temperature
521002 5 DEF pump direction valve high side current below normal or open circuit
521002 3 DEF pump direction valve high side short circuit to HIGH SOURCE
521002 4 DEF pump direction valve high side short circuit to GROUND
3361 31 DEF dosing valve powerstage driver chip over temperature
3361 3 DEF dosing valve low side short circuit to HIGH SOURC
DEF DOSING
3361 4 DEF dosing valve high side short circuit
VALVE
3361 14 DEF dosing valve current abnormal behaviour
3361 6 DEF dosing valve low side short circuit to GROUND or open load
3361 5 DEF dosing valve high side short circuit to HIGH SOURCE or open load
4342 5 DEF backflow line heater control circuit open circuit
4342 3 DEF backflow line heater control circuit short circuit to HIGH SOURCE
DEF BACKFLOW
4342 4 DEF backflow line heater control circuit short circuit to GROUND
LINE HEATER
4342 31 DEF backflow line heater ECU power stage over temperature
4355 4 DEF backflow line heater relay high side (heater, main relay) open circuit
4355 3 DEF backflow line heater relay low side (line relay) open circuit
4346 5 DEF pressure line heater control circuit open circuit
DEF PRESSURE 4346 3 DEF pressure line heater control circuit short circuit to HIGH SOURCE
LINE HEATER
4346 4 DEF pressure line heater control circuit short circuit to GROUND
4346 31 DEF pressure line heater ECU power stage over temperature
521001 31 DEF heater main relay ECU power stage over temperature
521001 3 DEF heater main relay circuit short circuit to HIGH SOURCE
DEF HEATER
521001 4 DEF heater main relay open circuit
MAIN RELAY
521003 3 DEF heater main relay control circuit short circuit to HIGH SOURCE
521003 4 DEF heater main relay control circuit short circuit to GROUND
DEF PRESSURE 4357 3 DEF pressure line heater relay low side (line relay) open circuit
LINE HEATER 4357 4 DEF pressure line heater relay high side (heater, main relay) open circuit
RELAY
4340 5 DEF suction line heater control circuit open circuit
DEF SUCTION 4340 3 DEF suction line heater control circuit short circuit to HIGH SOURCE
LINE HEATER
4340 4 DEF suction line heater control circuit short circuit to GROUND
4340 31 DEF suction line heater ECU power stage over temperature
DEF SUCTION 4354 3 DEF suction line heater relay low side (line relay) open circuit
LINE HEATER 4354 4 DEF suction line heater relay high side (heater, main relay) open circuit
RELAY
DEF SUPPLY 4344 3 DEF supply module heater control circuit short circuit to HIGH SOURCE
MODULE 4344 4 DEF supply module heater control circuit short circuit to GROUND
HEATER 4344 31 DEF supply module heater ECU power stage over temperature
DEF SUPPLY 4356 3 DEF supply module heater relay low side open circuit
MODULE 4356 4 DEF supply module heater relay high side (heater, main relay) open circuit
HEATER RELAY 4356 5 DEF supply module heater relay open circuit
DEF SUPPLY 4344 8 DEF supply module heater temperature signal in failure range
MODULE TEM- 4344 2 DEF supply module heater temperature signal in invalid range
PERATURE SEN- 4344 12 DEF supply module temperature measurement module is not responding
SOR
3363 5 DEF tank heater coolant valve solenoid open circuit
DEF TANK 3363 31 DEF tank heater ECU power stage over temperature
HEATER
3363 3 DEF tank heater coolant valve solenoid short circuit to HIGH SOURCE
3363 4 DEF tank heater coolant valve solenoid short circuit to GROUND
DOWNSTREAM 521004 11 Downstream NOx sensor missing
NOX SENSOR
UPSTREAM NOX 521005 11 Upstream NOx sensor missing
SENSOR
NOX SENSOR 521006 12 Nox sensor common plausibility error
COMMON
47
Degra Shut
dation down
521007 10 SCR system ERROR: DEF backflow line blocked or implausible
521007 14 SCR system ERROR: DEF pressure line or dosing valve blocked
521007 31 SCR system ERROR: DEF pressure stabilisation failure
4332 16 SCR system ERROR: DEF dosing pressure above normal
4332 18 SCR system ERROR: DEF dosing pressure below normal
4332 14 SCR system ERROR: Pressure drop test failure
4332 31 SCR system ERROR: Emptying not completed at previous shutdown
SCR SYSTEM
4332 11 SCR system ERROR: Pumped-Dosed quantities balance error
4332 0 SCR system ERROR: DEF over pressure detected
521008 1 SCR system ERROR: DEF pressure build up failure
521008 0 SCR system ERROR: DEF pressure reduction failure
4090 16 SCR system malfunction: NOx emission too HIGH
4090 18 SCR system malfunction: Measured NOx emission implausible
FADC 520229 13 3 Fast A/D Converter calibration error
CY146 520447 31 Reported SPI and COM-Errors of a Cy146
977 6 Fan control output current above normal
977 5 Fan control output open circuit
FAN
977 3 Fan control output short circuit to HIGH SOURCE
1639 18 Fan control underspeed or no signal detected
ENGINE 520230 31 Engine specification mismatch
PROTECTION
ALL 520231 31 PTO input error
APPLICATIONS 520232 31 Bad digital input configuration
VEHICLE 84 3 Vehicle speed sensor short to HIGH SOURCE
SPEED 84 4 Vehicle speed sensor short to GROUND
OPTIONAL 520205 31 Error in torque control input
COOLANT 109 3 Coolant pressure sensor voltage above normal or open circuit
PRESSURE 109 4 Coolant pressure sensor voltage below normal
520233 31 Diagnostic fault check to report "WDA active" due to errors in query-/
OCWDA (Opera- response communication
tion Condition of 520234 31 Diagnostic fault check to report "ABE active" due to undervoltage detection
WDA/ABE shut-
520235 31 Diagnostic fault check to report "ABE active" due to overvoltage detection
off)
520236 31 Diagnostic fault check to report "WDA/ABE active" due to unknown reason
2791 19 EGR Valve communication error
2791 12 EGR Valve initialization error
2791 31 EGR Valve not present
2791 14 EGR Valve overload
ZIZU EGR VALVE 2791 7 EGR Valve position deviation
2791 11 EGR Valve short cut
2791 0 EGR Valve temperature alert
2791 16 EGR Valve temperature warning
2791 10 EGR Valve torque limited
CUSTOMER 520237 31 Customer fault 1 via digital input
FAULT 520238 31 Customer fault 2 via digital input
START RELAY 677 5 Start relay current below normal or open circuit
677 3 Start relay low side voltage above normal or short to HIGH SOURCE
677 6 Start relay low side current above normal
1321 3 Start relay high side voltage above normal
1321 6 Start relay high side current above normal
626 3 Grid heater relay voltage above normal or short to HIGH SOURCE
GRID HEATER 626 6 Grid heater relay current above normal or short to GROUND
RELAY 626 5 Grid heater relay current below normal or open circuit
520239 6 DEF dosing valve after cooler current above normal or short to GROUND
DEF DOSING 520239 5 DEF dosing valve after cooler current below normal or open circuit
VALVE AFTER 520239 3 DEF dosing valve after cooler voltage above normal or short to HIGH
COOLER
SOURCE
SPN, FMI Fault codes according to the standard SAE J1939

Degradation 1 Fuel limit 75%, speed limit 2500 rpm Degradation 2 Fuel limit 50%, speed limit 1800 rpm
Degradation 3 Fuel limit 50%, speed limit 1800 rpm FLm Fuel limit by degradation curve
48
READING THE EEM4 FAULT CODES USING A SIGNAL LIGHT
The EEM4 engine control system includes an in-built self-diagnostics system. The active or recorded
fault codes can be shown using a separate blinking signal light directed by a diagnostic switch.
The signal light can be connected e.g. to the oil pressure light. In this case, as the engine is running, a
dropping oil pressure has higher priority and the result is that the signal light will be switched on all the
time.
Appearance of the Active Fault Reports
As the engine is running, the active fault reports make the signal
light blinking in periods of four seconds. The light is on for about
0,5 seconds.
The signal light is blinking in periods of four seconds also when

the current is switched on with the key and system has recorded 0,5 s 4s
a fault code.
Reading the Fault Codes
1. Turn the key into a position where the current is switched on.
Do not start the engine!
2,5 s 4s 5,5 s 6,5 s 8,0 s 9,5 s 10,5 s
2. Press the diagnostic switch three times within four seconds af-
ter turning the current on.
3. After a short pause the last fault code can be read from the sig-
nal light. This code is repeated until the diagnostic switch is- OFF
ON
pressed once. START
1
The fault code can be read as follows: a long blink (1,5 s) shows
the hundreds, a medium blink (1,0 s) shows the tens and a short
blink (0,5 s) shows the ones. The number of blinks, separated by
0,5 seconds intervals, tell the number of hundreds, tens and
ones. There is a 1,5 seconds pause between decades and a 2,5 2
seconds pause when the code begins from the start. As a sample X3
see the picture beside, fault code no. 123.
NOTE! If the code is only one number, for example 100, it is just
a 1,5 seconds blink and 2,5 seconds pause. 3
See fault codes on the page 44.
4. Press the diagnostic switch once.

4 X1
5. The signal light starts blinking the next fault code in the qeue.
If there were no more fault codes coming into the queue, the sig-
nal light starts to blink in periods of one second as a sign that
there were no more fault codes.
5
6. Press the diagnostic switch three times to clear the error log
and to end of the diagnostic. The diagnostic light is off. In case
the system uses the oil pressure light as the error diagnostic light,
it stays on (engine is not running).
6 X3
49
TROUBLESHOOTING
Always listen to engine noise and pay attention to how it operates. Eliminating a slight fault often pre-
vents a more serious one.
TROUBLE CAUSES
1 Loose or broken wire.
2 Battery discharged. This may be due to a slack-
A ENGINE CANNOT BE CRANKED ened or broken alternator belt.
3 Starter defective.
1 Fuel tank empty.
2 Fuel not fluid enough in cold weather (summer
quality).
3 Air in fuel system
4 Leak in fuel inlet or delivery pipe.
5 Clogged fuel filter or pipe.
6 Injectors defective.*
B ENGINE FAILS TO START 7 Retarded injection timing.
8 Low compression.*
a) leaky valves
b) piston rings sticking
c) cylinder head gasket damaged
d) broken valve spring
9 Rail overflow valve defective.
1 Air in fuel system

2 Fuel strainer in fuel tank air pipe clogged.
3 Clogged fuel filters or pipe
C ENGINE STARTS BUT STOPS 4 Clogged water separator.
AFTER A SHORT WHILE 5 EEM4 self-diagnostic has discovered fault in sys-
tem.*
1 Air in fuel system.

2 Clogged fuel filters or pipe.
3 Leak in fuel inlet or delivery pipe.
D ENGINE DOES NOT RUN 4 Injectors defective.*
SMOOTHLY 5 Low compression (see B 8 a - d).*
6 EEM4 control unit or speed sensors defective.*
50
TROUBLE CAUSES
1 Air filter clogged.
2 Turbocharger defective*
3 Air in fuel system.
4 Clogged fuel filter, pre-filter, water separator or
fuel pipe.
E ENGINE DOES NOT DEVELOP 6 Leak in fuel inlet or delivery pipe.
FULL POWER 7 Incorrect injection timing.*
8 Low compression (see B 8 a - d).*
9 EEM4 control unit defective.*
10 Rail overflow valve defective.
11 Limited engine power enabled (EEM4).
12 Engine running too cold.
13 Leakage in turbocharging system.
1 Incorrect fuel.
F ENGINE KNOCKING 3 Advanced injection timing.*
4 Low compression (see B 8 a-d).*
5 Excessive bearing clearance.*
1 Engine running too cold.
2 Engine has been idling for too long.
3 Air filter clogged.
4 Incorrect fuel.
5 Engine oil level too high.
6 Leak in fuel pipes.
G SMOKE OR SOOT IN EXHAUST 7 Clogged fuel filter, pre-filter, water separator
GASES 8 Injectors defective.*
9 Incorrect injection timing.*
10 Low compression (see B 8 a - d).*
11 EEM4 control unit defective.*
12 Turbocharger defective*
13 Leakage in turbocharging system.
1 Slack or broken fan belt.
2 Cooling system not completely filled. System
clogged.
3 Thermostat defective or removed (double-acting
H ENGINE OVERHEATS thermostat).
4 Thermostat upside down.
5 Radiator filler cap not pressure tight.
6 Overloading.
I ENGINE TENDS TO RACE OR 1 EEM4 control unit or speed sensors defective.*
FAILS TO MAINTAIN ITS STAND-
ARD SPEED
51
TROUBLE CAUSES
1 Engine has run short of oil.
2 Impurities in oil pressure regulating valve
3 Incorrect SAE grade of oil.
4 Oil too hot.
J OIL PRESSURE TOO LOW 5 Excessive bearing clearance.*
6 Idling speed too low.
7 Oil pressure sensor defective.
8 Oil pressure gauge shows incorrect reading.
9 Oil filter clogged.
10 Oil diluted by fuel.
* Consult an expert technician.
NOTE! See also engine control system fault codes.
52

SISU Service Information

Uploaded by

Copyright:

Available Formats

SISU Service Information

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SISU Service Information

Uploaded by

Copyright:

Available Formats

V837079421

4th Generation Engines

AGCO SISU POWER Inc.

Diesel Engines, After Sales

OPERATION AND DRIVING

ADDITIONAL SERVICE INSTRUCTIONS

Please fill your engine data here

Engine serial number

If you start the engine indoors, be sure to have proper ventilation.

Stop the engine always before service or repair work.

Avoid unnecessary idling of the engine.

All the gaskets of the engine are of non-asbestos material.

ENGINE TYPE DESIGNATIONS

LOCATION OF THE ENGINE SERIAL NO.

The engine serial number is always stamped on the cylin-

regulations large nonroad compression

This engine conforms to199 U.S EPA

MARKING OF THE EEM4 CONTROL UNIT

The specification of the application is indicated on the type

NOTE! The engine meets EU97/68/EC Stage lllB and EPA

Do not fit any components on the engine other than those

LIFTING THE ENGINE

*) Approximate dry weight without flywheel, electrics,

A = Engine lifting eyes

The general arrangement of the equipment is shown in the pictures on pages 6 - 7.

Sisu Power 74 ATI

AIR INTAKE SYSTEM

Cooling of Inlet Air (ATI-engines)

Parts of Fuel System

1. Fuel tank 7. High pressure pump

ENGINE CONTROL SYSTEM EEM4

Parts of Engine Control System

1. Electronic control unit (ECU) 11.Vehicle connector

Oil Pressure Regulating Valve

Oil Filter and Oil Cooler

Oil Filter and Oil Cooler (84, 98)

Cooling System (74 ATI)

Installing the Engine Heater

Install the coolant pre-heater according to the instructions of the manufacturer.

Precautions Concerning the Alternator and Electric Control Units

Starting with an Auxiliary Battery

SCR SYSTEM COMPONENTS AND THEIR FUNCTIONS

DNOX2.2 system includes several sensors:

SCR SYSTEM TECHNICAL DATA

OPERATION AND DRIVING

• lubrication oil level

• that the lubrication oil system and coolant system

• clean the cyclone of the air filter.

*)See instructions of the appliance for information about low

See starting instructions of the appliance.

See also actions before winter, page 39.

Engine is equipped with an electric pre / post

• Make sure the battery is sufficiently charged.

Warming up the engine

ATTENTION DURING OPERATION

It is dangerous to open the cap of the pressurised hot radiator!

Eventual running troubles, see chart in page 43.

COUPLING ADDITIONAL EQUIPMENT TO THE ENGINE

Hydraulic pump PTO with

Hydraulic pump PTO with