JCB Agco Sisu Power 4th Generation Engines Workshop Manual PDF

This workshop manual is intended to assist in the repair and service of Agco Sisu Power 4th Generation Engines, which are installed on JCB equipment.

The engines of the 4th generation (types 33, 44, 49, 66, 74, 84 and 98), as a rule, have the same design, therefore the same repair instructions usually apply to different types of engines. Differences between different types of engines that affect repair work are indicated in the technical data and repair instructions.

This repair manual does not cover the normal maintenance procedure, as explained in the 4th generation.

You can study the contents of this service manual in more detail with the help of screenshots and a list of content that is presented below. Installation manual does not require much time, there is an Instant Download. To work with the manual, you must use a program that reads PDF files.

Publication No. 9806-4100

Models covered:
4th Gen 33, 44, 49, 66, 74, 84 and 98.

CONTENT:

• GENERAL
  • TO THE USER
  • SAFETY INSTRUCTIONS
  • ENGINE TYPE DESIGNATIONS
  • LOCATION OF THE ENGINE SERIAL NO
  • MARKING OF THE EEM 4 CONTROL UNIT 
  • LIFTING THE ENGINE
• CONSTRUCTION
  • Technical Data
  • General
  • Cylinder Block
  • Flywheel Housing
  • Valve Mechanism 
  • Cylinder Head
  • Crank Mechanism 
  • Timing Gears
  • Lubricating System
  • Cooling System
  • Inlet and Exhaust System
• TECHNICAL DATA
  • Cylinder Block
  • Cylinder Liners
  • Cylinder Head
  • Valves and Rockers
  • Tappets and Push Rods
  • Camshaft
  • Crankshaft
  • Flywheel 
  • Balancing Unit
  • Timing Gears
  • Connecting Rod 
  • Piston, Rings, and Pin
  • Lubricating System
  • Oil Pump
  • Coolant Pump 
  • Thermostat
  • Turbocharger
• TIGHTENING TORQUES
• SPECIAL TOOLS
  • Cylinder Block
  • Timing Gear and Flywheel Housing
  • Cylinder Head and Valve Mechanism
  • Crank Mechanism
  • Coolant Pump
  • Fuel System
• WORK INSTRUCTIONS
• 1. CYLINDER BLOCK
  • 1.1. Measuring cylinder liner wear
  • 1.2. Removing cylinder liner
  • 1.3. Checking cylinder block
  • 1.4. Changing camshaft bushing
  • 1.5. Fitting plug at camshaft rear end
  • 1.6. Oversize bushings for camshaft
  • 1.7. Fitting plug at camshaft rear end (oversize bushings)
  • 1.8. Fitting cylinder liner
• 2. FLYWHEEL HOUSING
  • 2.1. Fitting flywheel housing 
  • 2.2. Changing crankshaft rear oil seal
• 3. CYLINDER HEAD
  • 3.1. Removing cylinder head
  • 3.2. Removing valves
  • 3.3. Checking cylinder head 
  • 3.4. Changing valve guides
  • 3.5. Machining valve seat
  • 3.6. Changing valve seat rings
  • 3.7. Grinding valves
  • 3.8. Fitting valves 
  • 3.9. Fitting cylinder head
• 4. VALVE MECHANISM
  • 4.1. Reconditioning valve mechanism
  • 4.2. Changing camshaft/camshaft gear
  • 4.3. Adjusting valves
• 5. CRANKSHAFT
  • 5.1. Removing crankshaft
  • 5.2. Checking crankshaft
  • 5.3. Changing crankshaft gears
  • 5.4. Fitting crankshaft
  • 5.5. Crankshaft hub piece
  • 5.6. Checking element of the rubber damper
  • 5.7. Viscose type Vibration Damper
• 6. CONNECTING RODS AND PISTONS
  • 6.1. Removing Pistons Together with Connecting Rods
  • 6.2. Changing Connecting Rod Bearings
  • 6.3. Checking Connecting Rod
  • 6.4. Changing Piston Rings
  • 6.5. Checking Pistons
  • 6.6. Fitting Piston Pin
  • 6.7. Fitting Piston Together with Connecting Rod
• 7. COUNTERBALANCE (44- and 49-Engines)
  • 7.1. Removing and Disassembling Counterbalance Unit
  • 7.2. Reconditioning Counterbalance Unit
  • 7.3. Fitting Counterbalance Unit
  • 7.4. Changing Crankshaft Gear Rim
• 8. FLYWHEEL
  • 8.1. Changing Starter Ring Gear on Flywheel
  • 8.2. Fitting Flywheel
• 9. TIMING GEAR ASSEMBLY
  • 9.1. Removing Timing Gear Casing
  • 9.2. Fitting Timing Gear Casing
  • 9.3. Fitting the Crankshaft Hub, 98
  • 9.4. Power Take-off
  • 9.5. Fan Drive Device 
• 10. LUBRICATION SYSTEM
  • 10.1. Oil Pressure Regulating Valve
  • 10.2. Removing and Dismantling Lubricating Oil Pump
  • 10.3. Assembling and Fitting Lubricating Oil Pump 
  • 10.4. Piston Cooling Nozzles 
  • 10.5. Fitting Oil Sump Gasket
  • 10.6. Lubricating Oil Cooler 
  • 10.7. Lubricating Oil Quality Requirements
  • 10.8. Oil Capacities
  • 10.8. Closed Crankcase Ventilation (CCV)
• 11. COOLING SYSTEM
  • 11.1. Quality Requirements for Coolant
  • 11.2. Thermostat
  • 11.3. Reconditioning Coolant Pump 
  • 11.4. Coolant Pumps with Heavy Duty Bearings
  • 11.5. Installing the Cylinder Head Connection Part
• 12. INLET AND EXHAUST SYSTEM
  • 12.1. Checking the Air Cleaner 
  • 12.2. Checking the Inlet and Exhaust Pipes
  • 12.3. Checking the Turbocharger
  • 12.4. Fitting the Turbocharger
  • 12.5. EGR System 
• 13. FUEL SYSTEM
  • 13.1. Technical Data
  • 13.2. Bleeding Fuel System
  • 13.3. Measuring Fuel Feed Pressure
  • 13.4. Inspecting Injectors 
  • 13.5. High-Pressure Pump
  • 13.6. Rail
  • 13.7. Fuel Quality Requirements
  • 13.8. SCR System
• 14. EEM4 ENGINE CONTROL SYSTEM
  • 14.1. Construction of the EEM4
  • 14.2. EEM4 Engine Control System, Description
  • 14.3. Service Tool of the EEM4 System
  • 14.4. Changing the Control Unit (ECU)
  • 14.5. Wiring Sets
  • 14.6. Sensors of the Engine Control System
• 15. ELECTRICAL SYSTEM
  • 15.1. Alternators
  • 15.2. Starters