Jcb Engines Agco Sisu Power Tier 4 Final Awf Engines Service Manual

Workshop Service Manual

Linnavuori AGCO Power - Linnavuorentie 8-10 - FIN-37240 Linnavuori, Nokia, Finland © AGCO 2013

December 2013 8370 79873 English

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Table of contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.2 To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.3

1.2.1 1.2.2 1.2.3 1.2.4

Engine type designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Location of the engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Marking of the engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Lifting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Engine construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.3.1 Engine construction overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.3.3 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.3.4 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.3.5 Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.3.6 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.3.7 Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.3.8 Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.3.9 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 1.3.10 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 1.3.11 Air control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2 2.3

2.1.1 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.1.2 Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.1.3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.1.4 Valves and rockers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.1.5 Tappets and push rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.1.6 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.1.7 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.1.8 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2.1.9 Balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2.1.10 Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2.1.11 Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2.1.12 Piston, rings and pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 2.1.13 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2.1.14 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2.1.15 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 2.1.16 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 2.3.1 Cylinder block tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 2.3.2 Timing gear and flywheel housing tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2.3.3 Cylinder head and valve mechanism tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2.3.4 Crank mechanism tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2.3.5 Coolant pump tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 2.3.6 Engine control system and fuel system tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.1.1 Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

8370 79873

Table of contents 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9

Removing cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Fitting plug at camshaft rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Fitting plug at camshaft rear end (oversize bushings) . . . . . . . . . . . . . . . . . . . . . . . 3-9 Fitting cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.2 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3.2.1 Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3.2.2 Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3.3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 3.3.1 Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 3.3.2 Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 3.3.3 Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 3.3.4 Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 3.3.5 Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 3.3.6 Changing valve seat rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 3.3.7 Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 3.3.8 Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 3.3.9 Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 3.4 Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 3.4.1 Reconditioning valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 3.4.2 Changing camshaft or camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 3.4.3 Preparations for valve adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 3.4.4 Adjusting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 3.5 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 3.5.1 Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 3.5.2 Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 3.5.3 Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 3.5.4 Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3.5.5 Crankshaft hub piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 3.5.6 Viscose type vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 3.6 Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 3.6.1 Removing pistons together with connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 3-34 3.6.2 Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 3.6.3 Changing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 3.6.4 Checking pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 3.6.5 Fitting piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 3.6.6 Fitting piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 3.7 Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 3.7.1 Piston pin bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 3.7.2 Big-end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 3.8 Counterbalance in 4 cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3.8.1 Removing and disassembling counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3.8.2 Reconditioning counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3.8.3 Fitting counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 3.8.4 Changing crankshaft gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 3.9 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 3.9.1 Changing starter ring gear on flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 3.9.2 Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 3.10 Timing gear assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 3.10.1 Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 3.10.2 Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 3.10.3 Fitting the crankshaft hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 8370 79873

Table of contents

3.11

3.12

3.13

3.14

3.15

3.10.4 Power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.5 Fan drive device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.1 Oil pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.2 Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.3 Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.4 Piston cooling nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.5 Fitting oil sump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.6 Lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.7 Removing lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.8 Fitting lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.9 Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.10 Oil sump capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.11 Closed crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.1 Coolant quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.2 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.3 Reconditioning coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.4 Installing the cylinder head connection part . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air control system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.1 Checking the air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.2 Checking the inlet and exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.3 Removing actuator of the high pressure turbocharger . . . . . . . . . . . . . . . . . . . .

3.13.4 Fitting actuator of the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . .

3.13.5 Removing the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.6 Checking the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.7 Fitting the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.8 Removing the EGR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.9 Fitting the EGR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.10 Removing the EGR actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.11 Fitting the EGR actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.12 EGR link rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.1 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.2 Technical data of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.3 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.4 Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.5 Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.7 Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.8 Fuel quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14.9 SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.1 Service tool of the engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.2 Electronic diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.3 Changing the electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.4 Wiring sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-51 3-52 3-53 3-53 3-53 3-54 3-54 3-55 3-56 3-56 3-57 3-57 3-58 3-58 3-60 3-60 3-60 3-62 3-67 3-69 3-69 3-69 3-70 3-70 3-70 3-70 3-71 3-72 3-72 3-72 3-73 3-73 3-74 3-74 3-75 3-76 3-77 3-77 3-79 3-81 3-84 3-87 3-92 3-93 3-94 3-96 3-98

5 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

8370 79873

Table of contents

8370 79873

Table of contents

1. Introduction 1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.2 To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.3

1.2.1 1.2.2 1.2.3 1.2.4

Engine type designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Location of the engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Marking of the engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Lifting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Engine construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.3.1 Engine construction overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.3.3 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.3.4 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.3.5 Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.3.6 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.3.7 Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.3.8 Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.3.9 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 1.3.10 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 1.3.11 Air control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

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Table of contents

1-2

8370 79873

1. Introduction

1.1 Safety instructions There is always the risk of injury when using or servicing the engine. Before starting the service, please ensure you have read and understood the following safety instructions and remarks!

• Do not start any repair work that you do not fully understand.

• Make sure that the location and surroundings in which you are carrying out the repair provide a safe environment in which to work.

• Always ensure the location is clean and free of clutter.

• Do not use faulty or otherwise unsuitable tools.

• Remove all rings, chains and watches before starting work.

• Use up-to-date protection equipment while you work. For example, eye protection, as you will be working with compressed air for cleaning, grinding, hammering or similar.

• Use a lifting device for lifting and transporting heavy (over 20 kg) pieces. Ensure all lifting hooks and chains are in good condition. The lifting eyes on the engine must not be subjected to side forces during lifting.

• Never work under an engine that is hanging from a lifting device or raised up on a jack. Always use strong supports before starting the work.

• Use only genuine AGCO Parts spare parts.

NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers when opening joints.

• 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 when the engine is running! Ensure that loose clothing or long hair does not get caught in the rotating parts of the engine.

If you start the engine indoors, ensure that there is proper ventilation.

Never use an aerosol starting aid! (Risk of explosion, personal injuries and engine damage.)

When you are operating the engine or working near it, use ear protection to avoid noise injuries.

Always stop the engine before starting any servicing or repair work.

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

Open the radiator cap with care when the engine is hot, as the cooling system is pressurised. The cooling liquid and lubrication oil of a hot engine will cause injury if they come into contact with skin.

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

Never allow a naked flame, smoking or sparks near the fuel system or batteries, especially when loading batteries, as these are explosive.

Always disconnect the negative (-) battery cable when servicing or repairing the electric system.

At temperatures in excess of 300°C, e.g. if the engine is burnt by a fire, the viton seals of the engine (i.e. the undermost cylinder liner O-ring) produce very highly corrosive hydrofluoric acid. Do not touch with bare hands when viton seals are 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 relevant disposal point provided by the authorities concerned.

NOTE: Never destroy viton seals by burning!

• When checking fuel injectors do not allow the jet of high-pressure fuel to come into contact with your skin. The fuel penetrates the skin causing severe injuries. Get medical help immediately!

• The fuel, lubricating oil and coolant cause long-lasting irritation on contact with skin.

• If you are carrying out welding or similar high current operations for the appliance, we recommend that you disconnect the Engine control unit main connector before starting work.

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1-3

1. Introduction • Avoid unnecessary idling of the engine.

• Do not let oil and other liquids to the environment when servicing the engine. Take them to a proper disposal point.

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

• Be careful when washing the engine with high-pressure washing machine equipment. Do not use high pressure to wash e.g. the electric and fuel equipment or the radiator because they can easily be damaged. To get humidity removed, it is recommended to run the engine after washing.

1-4

8370 79873

1. Introduction

1.2 To the user This Workshop Manual is intended to assist with workshop operations and repair work.

5th Generation engines (types 33, 44, 49, 66, 74, 84 and 98) are generally of the same construction, so the same repair instructions will usually apply to various engine types. The differences between the various engine types, which affect repair work, are mentioned in the technical data and repair instructions. All measurements are in millimetres and valid when the temperature of the parts is +20°C, unless otherwise stated.

Engines fulfil the emission requirements set by the authorities (AWF/ATF: EU97/68/EC Stage IV and EPA 40 CFR 1039 Tier 4 Final). The manufacturer guarantees that all engines of this type are equivalent to the engine that is officially approved. Please note that the service schedule should be followed carefully, especially when performing periodical maintenance. Any adjustment and repair work to the injection system or the engine control unit should only be carried out by a representative authorised by AGCO Power Inc. When performing any service or repair work, only use original AGCO Parts spare parts.

Inadequate or delayed service and the use of parts other than original AGCO Parts spare parts will invalidate the responsibility of AGCO Power Inc. with respect to the fulfilment of the emission requirements.

NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers when opening joints.

Before starting any repair work, please read the safety instructions at the beginning of this book. Make sure that you have all the necessary tools, parts and accessories to hand. The special tools mentioned in the work instructions speed up and facilitate the work and contribute to successful execution of the work.

An engine which has undergone repairs must be run in just like a new one.

Should the engine require work not described in this manual, please consult your local agent or the Service Department of AGCO Power Inc., Linnavuori, Finland. To facilitate consulting, find out the following facts about the engine before contacting us: • engine type • engine number • model or equipment • hours operated or kilometres driven This Workshop Manual does not cover the regular service procedure as this is explained in the 5th Generation series Operator's Manual.

As AGCO Power Inc. is continuously developing its products, all rights are reserved to alter the specifications, accessories and the service and repair procedure without separate notice.

NOTE: AGCO Power Inc. takes no responsibility for any damages caused because of possible incorrect information in this manual. Distribution of this manual in printed or electronic form is not allowed without our prior agreement.

1.2.1 Engine type designations

8370 79873

1-5

1. Introduction

Fig. 1

1.2.2 Location of the engine serial number

1-6

8370 79873

1. Introduction The engine serial number is always stamped on the cylinder block as the picture shows.

The serial number is also marked on the type plate.

Engines have an electronic serial number data which is readable with electronic service tool. The data includes also detailed specification, operation history and service information.

Fig. 2

1.2.3 Marking of the engine control unit

8370 79873

1-7

1. Introduction The specification of the application is indicated on the type plate of the engine control unit (ECU).

This specification must always be stated when ordering a control unit or asking for adjusting settings.

NOTE: Engine with aftertreatment system meets EU97/68/EC Stage lV and EPA 40 CFR 1039 Tier 4 final emission requirements.

Do not fit any components on the engine other than those originally intended for it. The use of other than original AGCO Parts spare parts invalidates the responsibility of AGCO Power Inc. on the meeting of the emission requirements.

Fig. 3

1.2.4 Lifting the engine DANGER: Safe lifting of the engine is done with a lifting device where the lifting force affects the lifting eyes vertically.

1-8

8370 79873

1. Introduction A = Engine lifting eyes

Fig. 4

Weight of engine

Engine type

Weight kg[1]

33

300

44

345

49

345

66

515

74

525

84

665

98

790

[1]

8370 79873

Approximate dry weight without flywheel, electrics, CCV , EGR and SCR system components

1-9

1. Introduction

1.3 Engine construction 1.3.1 Engine construction overview The 5th Generation engine series consists of water-cooled in-line diesel engines with three, four, six and seven cylinders. The turbocharged engines are equipped with wet, changeable cylinder liners.

All the engine types 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.

1.3.2 Technical data Principal dimensions and data Engine type

33

44

49

66

74

84

98

Number of cylinders

3

4

4

6

6

6

7

Displacem ent (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

Combusti on

Direct injection

Direct injection

Direct injection

Direct injection

Direct injection

Direct injection

Direct injection

Injection advance

Automatic adjusted

Automatic adjusted

Automatic adjusted

Automatic adjusted

Automatic adjusted

Automatic adjusted

Automatic adjusted

Valve clearance, intake and exhaust (mm)

0,35 (cold or hot)

0,35 (cold or hot)

0,35 (cold or hot)

0,35 (cold or hot)

0,35 (cold or hot)

0,35 (cold or hot)

0,35 (cold or hot)

Direction of rotation from the engine front

Clockwise

Clockwise

Clockwise

Clockwise

Clockwise

Clockwise

Clockwise

1-10

8370 79873

1. Introduction

Fuel system Engine type

33

44

49

66

74

84

98

Fuel injection system

Bosch Common Rail

Bosch Common Rail

Bosch Common Rail

Bosch Common Rail

Bosch Common Rail

Bosch Common Rail

Bosch Common Rail

Fuel

The fuel must be according to norm EN 590:2009, see Fuel quality requirem ents

The fuel must be according to norm EN 590:2009, see Fuel quality requirem ents

The fuel must be according to norm EN 590:2009, see Fuel quality requirem ents

The fuel must be according to norm EN 590:2009, see Fuel quality requirem ents

The fuel must be according to norm EN 590:2009, see Fuel quality requirem ents

The fuel must be according to norm EN 590:2009, see Fuel quality requirem ents

The fuel must be according to norm EN 590:2009, see Fuel quality requirem ents

Injection order

1-2-3

1-2-4-3

1-2-4-3

1-5-3-6-2-4

1-5-3-6-2-4

1-5-3-6-2-4

1-2-4-6-7-5 -3

Injection pressure

Max. 1800 bar

Max. 1800 bar

Max. 2000 bar

Max. 2000 bar

Max. 2000 bar

Max. 2000 bar

Max. 2000 bar

Fuel filter: Pre-filter

10 µ

10 µ

10 µ

10 µ

10 µ

10 µ

10 µ

Fuel filter: Main filter

5µ

5µ

5µ

5µ

5µ

5µ

5µ

Lubrication system Lubrication system Oil pressure in hot engine at running speed

2,5 - 5 bar

Oil pressure at idle speed, min

1,5 bar

Oil capacity

See Oil sump capacity

Oil quality requirements

See Lubricating oil quality requirements

8370 79873

1-11

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