Page 1 Workshop Service Manual 4th Generation Engines AGCO POWER Linnavuori November 2014 AGCO Power - Linnavuorentie 8-10 - FIN-37240 8370 79492 Linnavuori, Nokia, Finland EAME © AGCO 2014 English...
Page 3: Table Of Contents
1.3.9.1 Oil pressure regulating valve ....... . . 1-17 1.3.9.2 Oil filter and oil cooler in 33-74 engines ......1-17 1.3.9.3 Oil filter and oil cooler in 84-98 engines .
Page 4 3.1.3 Checking cylinder block ..........3-5 3.1.4 Changing camshaft bushing (33-49 engines) ......3-6 3.1.5 Changing camshaft bushing (66-98 engines) .
Page 5 3.6.4 Changing piston rings ........
Page 6 Table of contents 3.13 Fuel system ........... . . 3-61 3.13.1 Bleeding the fuel system .
Page 7: Introduction
1.3.9.2 Oil filter and oil cooler in 33-74 engines ......1-17...
Page 8 Table of contents 4th Generation Engines 8370 79492...
Page 9: Safety Instructions
1. Introduction 1.1 Safety instructions WARNING: In the use and service of the engine there is always the possibility of injury. Before starting the service read and understand the safety instructions and remarks! • Do not start any repair work that you do not fully understand. •...
Page 10 1. Introduction • Do not let oil and other liquids to the environment when servicing the engine. Take them to a proper disposal point. • Use only genuine AGCO Parts spare parts. NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers when opening joints.
Page 11 This Workshop Manual is intended to assist with workshop operations and repair work. 4th 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.
Page 12: Engine Type Designations
1. Introduction 1.2.1 Engine type designations Basic type 74 = cylinder displacement, decilitres A = aftertreatment system Turbocharged engine W = wastegate turbo T = standard turbo Equipped with intercooler I = air to air C = medium duty engine G = generating set engine Fig.
Page 13: Location Of The Engine Serial Number
1. Introduction 1.2.2 Location of the engine serial number 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 engine control unit (ECU) service tool.
Page 14: Marking Of The Engine Control Unit
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...
Page 15: Starting The Engine After Major Maintenance
1. Introduction A = Engine lifting eyes Fig. 4 Weight of engine Engine type Weight kg Approximate dry weight without flywheel, electrics, CCV , EGR and SCR system components 1.2.5 Starting the engine after major maintenance Some parts in the exhaust system can be damaged easily by increased amount of oil and impurities. Excessive oil can occur after a major engine overhaul, for example when the pistons are lubricated during the assembly.
Page 16 1. Introduction Procedure Do not connect the exhaust system to the engine, if there can be extra oil or impurities in the engine after any maintenance work or engine overhaul. Run the engine 1-2 minutes on high idle. Running the engine burns possible extra oil and impurities from the engine. NOTE: Excessive amount of oil can damage the catalysts.
Page 17: Engine Construction
1.3 Engine construction 1.3.1 Engine construction overview AGCO POWER engines 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.
Page 18: Lubrication System
1. Introduction Engine type D975 1-D/2- D975 1-D/2- D975 1-D/2- D975 1-D/2- D975 1-D/2- D975 1-D/2- D975 1-D/2- D, see the D, see the D, see the D, see the D, see the D, see the D, see the information information information information...
Page 19: Scr System Technical Data
The seal between the lower part of the cylinder liner and the cylinder block is achieved by three O-rings. The O-rings are fitted in grooves in the liner in 33-, 44-, 49-, 66- and 74-engines . The O-rings are fitted in grooves in the cylinder block in 84- and 98-engines .
Page 20: Cylinder Head
1. Introduction 1.3.6 Cylinder head A three cylinder engine has one cylinder head.There is one cylinder head in four cylinder engine. A six cylinder engine has two cylinder heads. The 98 engine has two cylinder heads: one for three cylinders (front) and one for four cylinders (rear).
Page 21: Timing Gears
1. Introduction 1.3.8 Timing gears Camshaft gear Idler gear High-pressure pump gear Crankshaft gear PTO gear Small idler gear The timing gear drives the camshaft, high-pressure pump and oil pump. The timing gear train consists of hardened, helically cut gear wheels. The gears are encased by the timing gear casing, which is fitted to the front of the engine.
Page 22: Lubrication System
The engine is equipped with closed crankcase ventilation (CCV) system. It is of centrifugal oil separator type on 84 and 98 engines. There is Super Impactor type CCV system with boost air on 33, 44, 49, 66 and 74 engines. CCV system is maintenance-free.
Page 23: Oil Filter And Oil Cooler In 33-74 Engines
At idling the pressure is 1,5 bar minimum. Fig. 9 1.3.9.2 Oil filter and oil cooler in 33-74 engines Oil cooler Oil filter Coolant drain plug Oil pressure regulating valve The oil filter is of main flow type.
Page 24: Cooling System
40 - 60 % of water and antifreeze. See the information for coolant quality requirements. Fig. 12 Cooling system Fig. 13 Cooling system 1.3.10.1 Thermostat 33 - 49 engines The engine has a 2-way thermostat. Its opening temperature is 83°C. There is no separate winter thermostat. Fig. 14...
Page 25: Air Intake System
1. Introduction 66 - 98 engines The engine has two separate thermostats. The thermostats differ in type and opening temperature. The smaller, single-acting thermostat opens at 79°C and the other, double-acting type, at 83°C. When the coolant temperature is below the thermostat opening temperature, the coolant (A) circulates through the by-pass hole into the coolant pump.
Page 26: Cooled Egr System
1. Introduction The air intake system includes pre-filter (or cyclone, if installed), air filter, turbocharger, intercooler, intake 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.
Page 27: Egr Cooler
Engine control unit Actuator The cooled exhaust gas recirculation system (EGR) used on some AGCO POWER engines is controlled by electronic engine control unit (ECU). Part of exhaust gases is led from exhaust manifold (1) through EGR valve (2) to EGR cooler (3) where they are cooled with engine coolant. The cooled exhaust gas is mixed with fresh intake air in intake manifold (4) before it flows to combustion chamber.
Page 28: Scr-System
1.3.13 SCR-system 1.3.13.1 SCR system overview AGCO POWER engines have 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.
Page 29: Scr System Components And Their Functions
1. Introduction 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.
Page 30: Engine Control System
1. Introduction Sensors DNOX2.2 system includes several sensors: • NOx sensors • Exhaust temperature sensors • DEF tank level sensor • Temperature sensors: DEF tank, Supply Module internal 1.3.14 Engine control system The basic function of the electric control of the engine is continuous adjustment and measuring of the load, quantity of fuel and rotating speed.
Page 31 1. Introduction Fig. 20 Example of engine control system construction (3 cylinder engine) Electronic control unit (ECU) Fuse, grid heater (2 ) Oil pressure sensor Wiring set (10) Relay Fuel pressure sensor (11) Inlet air pre-heater relay Fuel temperature sensor (12) Injector wiring Boost pressure sensor (13) EGR actuator...
Page 32 1. Introduction Fig. 21 Example of engine control system construction (6 cylinder engine) Electronic control unit (ECU) Speed sensor (crankshaft) (10) Injector wiring Oil pressure sensor (11) Vehicle connector Speed sensor (camshaft) (12) Inlet air heater Coolant temperature sensor (13) Inlet air heater solenoid Rail pressure sensor (14) Heater wiring Boost pressure sensor...
Page 33: Service Tool Of The Engine Control System
EEM4 system. The service tool and the additional parts are sold and supplied by AGCO Power Inc. Service Fig. 23 Department. Adapter for application connector (pin-to-pin)
Page 34 1. Introduction 1-28 4th Generation Engines 8370 79492...
Page 35: Specifications
2.5 Terminal diagram (3-6 cylinder engines) ....... . . 2-33 2.6 Terminal diagram (7 cylinder engines)
Page 36 Table of contents 4th Generation Engines 8370 79492...
Page 37: Cylinder Block
Cylinder block (33, 44, 49, 66, 74 engines) Holes for guide pins 13.250 - 13.320 mm Main bearing housing diameter (33, 44, 49 engines) 91.000 - 91.025 mm Main bearing housing diameter (66 and 74 engines) 96.000 - 96.025 mm Cylinder liner location, diameter: •...
Page 38: Cylinder Head
Height of cylinder liner flange, 3rd oversize 9.23 - 9.25 mm Outer diameter of cylinder liner flange 131.700 - 131.800 mm 33, 44, 49, 66, 74 engines Outer diameter of cylinder liner guide: • at upper end of liner • 124.475 - 124.500 mm •...
Page 39: Valves And Rockers
2. Specifications Cylinder head • inlet valve • 35°+20' • exhaust valve • 45°+20' Width of valve seat: • inlet valve • 2.2 mm • exhaust valve • 2.0 mm Diameter of exhaust valve seat ring 36.060 - 36.122 mm Diameter of exhaust valve seat rings recess 36.000 - 36.025 mm Diameter of exhaust valve seat ring (overhaul part...
Page 40: Tappets And Push Rods
Diameter of tappet bore in cylinder block 30.000 - 30.043 mm Max. permissible push rod deflection (when free) 0.4 mm Overall length of push rod (33-74 engines) 245 - 246.3 mm Overall length of push rod (84-98 engines) 286 - 287.3 mm...
Page 41: Camshaft
2. Specifications 2.1.6 Camshaft Camshaft (33, 44 and 49 engines) Diameter of camshaft bearing journal no. 1 49.875 - 49.900 mm Diameter of camshaft bearing journals others 49.885 - 49.910 mm Camshaft clearance in bearing bush no. 1 0.140 - 0.185 mm Camshaft clearance in bearing bush nos.
Page 42: Crankshaft
2. Specifications 2.1.7 Crankshaft Crankshaft (33, 44, 49, 66 and 74 engines) Crank pin diameter: • standard • 67.981 - 68.000 mm • 1st undersize 0.25 mm • 67.731 - 67.750 mm • 2nd undersize 0.50 mm • 67.481 - 67.500 mm •...
Page 43 2. Specifications Crankshaft (33, 44, 49, 66 and 74 engines) • 4th undersize 1.50 mm • 3.705 - 3.715 mm Main bearing clearance 0.050 - 0.127 mm Length of thrust bearing journal (journal nearest to flywheel): • standard (fixed thrust plates) •...
Page 44 2. Specifications Crankshaft (84 engine) Main bearing journal diameter: • standard • 89.985 - 90.020 mm • 1st undersize 0.25 mm • 89.735 - 89.770 mm • 2nd undersize 0.50 mm • 89.485 - 89.520 mm • 3rd undersize 1.00 mm •...
Page 45 2. Specifications Maximum permissible ovality and other deformity 0.03 mm of crank pins or journals Crankshaft unbalance 1.0 Ncm max. Number of teeth on trigger wheel 60-2 Crankshaft (98 engine) Crank pin diameter: • standard • 72.981 - 73.000 mm •...
Page 46: Flywheel
2. Specifications Other crankshaft journals cannot be ground longer. Rounded corner of crank pins and journals R4+0.5 mm Crankshaft end float 0.100 - 0.380 mm Maximum permissible ovality and other deformity 0.03 mm of crank pins or journals Crankshaft unbalance 1.0 Ncm max.
Page 47: Connecting Rod
Maximum permissible weight difference between 20 g connecting rods in the same engine Weight marking (letter) at lower end. 33, 44, 49, 66 and 74 engines Inside diameter of piston pin bush (with bush 40.025 - 40.040 mm pressed into connecting rod) Outside diameter of piston pin bush (std) 44.080 - 44.120 mm...
Page 48: Piston, Rings And Pin
Connecting rod big-end bore 76.730 - 76.749 mm 2.1.12 Piston, rings and pin Piston, rings and pin (33, 44, 49, 66 and 74 engines) Piston diameter: 107.883 - 107.897 mm • 17 mm from lower edge (33, 44, 66 engines) 107.893 - 107.907 mm...
Page 49 2. Specifications Piston, rings and pin (33, 44, 49, 66 and 74 engines) 2.470 - 2.490 mm • 2nd ring 2.970 - 2.990 mm • 3rd ring Piston ring gap (with piston fitted in cylinder): 0.30 - 0.45 mm • 1st ring 0.80 - 1.00 mm...
Page 50: Lubrication System
Oil filter by-pass valve opens at a pressure 2 ± 0.5 bar difference of Oil pressure regulating valve (33, 44 and 49 engines) 48.2 - 51.8 mm • Free length of oil pressure valve spring 28.5 mm / 89 N •...
Page 51: Oil Pump
2. Specifications 2.1.14 Oil pump Oil pump (33, 44 and 49 engines) Backlash between gears when crankshaft lies firmly against the lower side of the main bearings: 0.05 - 0.25 mm • crankshaft gear-lubricating oil pump gear 0.16 - 0.26 mm •...
Page 52: Thermostat
2. Specifications Oil pump (66 and 74 engines) Thickness of gears 32.000 - 32.027 mm End play of gears 0.03 - 0.11 mm Depth of housing 32.000 - 32.043 mm Oil pump (84 and 98 engines) Backlash between gears when crankshaft lies firmly against the lower side of the main bearings: 0.05 - 0.25 mm •...
Page 53: Turbocharger
2. Specifications 2.1.16 Turbocharger S100 S200 S300 S400 Axial clearance maximum 0.10 mm 0.10 mm 0.12 mm 0.11 mm Radial clearance (compressor end) maximum 0.82 mm 0.88 mm 0.88 mm 1.00 mm Compressor wheel lock nut torque 6.8 Nm 13.6 Nm 20.3 Nm 41.8 Nm Compressor housing screws torque...
Page 54: Tightening Torques
Connecting rod screws • M12 • 40 Nm > 80 Nm + 90° • M14 • 40 Nm > 80 Nm + 90° + 90° Crankshaft nut (33/44/49) Crankshaft nut (66/74/84/98) 1000 Crankshaft pulley screws Crankshaft pulley screws (74/84/98) Flywheel screws...
Page 55 2. Specifications Object Injector (CRI2_16) retaining screw Injector wire nuts (M4) High pressure pump gear nut Fuel filter elements Pre-filter water detector Compressor gear nut (1 and 2 cylinder) 160 (LH thread) Self carrying oil sump screws and engine bracket screws Thread General torque values Thread...
Page 56: Special Tools
2. Specifications 2.3 Special tools 2.3.1 Cylinder block tools Fig. 1 Ref. Description Order number Puller for cylinder liner 9051 73100 Puller for cylinder liner 9104 51500 Milling cutter for cylinder 9101 65600 liner seat Milling cutter for cylinder 9104 52000 liner seat Spare cutting blade for 9045 87600...
Page 57: Timing Gear And Flywheel Housing Tools
2. Specifications 2.3.2 Timing gear and flywheel housing tools Fig. 2 Description Order number Centring tool for flywheel 9052 46400 housing Centring tool for flywheel 9104 52700 housing Drift for fitting rear 9052 46300 crankshaft seal Drift for fitting rear 9104 52600 crankshaft seal Drift for fitting front...
Page 58: Cylinder Head And Valve Mechanism Tools
2. Specifications 2.3.3 Cylinder head and valve mechanism tools Fig. 3 Description Order number Tightening tool for injector 9201 79670 wiring connector Fitting tool for valve stem 9201 85580 gasket Milling cutter kit for valve 8370 62635 seat Milling tool for injector seat 9120 85400 Drift for removing valve 9210 85300...
Page 59: Crank Mechanism Tools
2. Specifications 2.3.4 Crank mechanism tools Fig. 4 Description Order number Puller for crankshaft gears 9052 48800 Spanner for crankshaft nut 9024 55800 Puller for crankshaft hub 9201 82390 Piston fitting tool 9201 85840 Piston fitting tool 9231 06340 Piston ring pliers 9052 46900 Drift for fitting oil deflector 9103 94900...
Page 60: Coolant Pump Tools
2. Specifications 2.3.5 Coolant pump tools Fig. 5 Description Order number Puller for coolant pump 9101 93200 impeller Drift for fitting coolant pump 9201 97870 water seal Drift for fitting coolant pump 9201 97880 water seal Drift for fitting coolant pump 9201 89320 bearing (6100 60124) Fitting tool for coolant pump...
Page 61: Engine Control System Tools
2. Specifications 2.3.6 Engine control system tools Fig. 6 Description Order number Sisutronic EEM 4 service 8370 79541 tool (incl. USB adapter) Adapter for application 8370 79553 connector Extension cable (L = 5 m) 8368 62483 2.3.7 Maintenance and troubleshooting tools Return quantity tester 8370 79449 Fig.
Page 62 2. Specifications SCR tool kit 8370 91048 SCR tool kit includes: • Pressure test unit 0-16 bar • Measuring jug with adapter for dosing module • Scale with calibration weight • Adapter tube 9.5x20 transparent (2 pcs.) • Adapter tube 8.0x20 transparent •...
Page 63: Liquid Quality Requirements
2. Specifications 2.4 Liquid quality requirements 2.4.1 Lubricating oil quality requirements Use lubricating oils fulfilling following quality grades. API-grade ACEA-grade Engine type CJ-4 Tier 4i / Stage IIIB engines CI-4 Tier 3 / Stage IIIA engines and earlier emission requirements fulfilling engines Select viscosity grade from Oil viscosity -table corresponding to outside temperature.
Page 64: Fuel Quality Requirements
EN 141214:2008. Fuels according to ASTM D975 may contain up to 5% FAAE (fatty acid alkyl ester) type biodiesel according to ASTM D6751-08. Contact AGCO Power R&D for more information of using different types of biodiesel! 2-30...
Page 65 Fig. 13 Alternative fuels Using diesel fuel according to European norm EN 590:2009 or ASTM D 975 1-D or 2-D, all AGCO POWER engines have full warranty for the specified warranty period and the engines will work well with good reliability and long life time.
Page 66 2. Specifications NOTE: Use of fuel not meeting these requirements may result as reduced performance and shorter engine life. It also invalidates the engine warranty. 2-32 4th Generation Engines 8370 79492...
Page 67: Terminal Diagram (3-6 Cylinder Engines)
2. Specifications 2.5 Terminal diagram (3-6 cylinder engines) Fig. 14 4th Generation Engines 2-33 8370 79492...
Page 68: Terminal Diagram (7 Cylinder Engines)
2. Specifications 2.6 Terminal diagram (7 cylinder engines) Fig. 15 2-34 4th Generation Engines 8370 79492...
Page 69: Maintenance
3.1.4 Changing camshaft bushing (33-49 engines) ........
Page 70 3.10.10 Closed crankcase ventilation ......... . 3-50 3.10.10.1 Installing the closed crankcase ventilation system components in 33 - 74 engines .
Page 71 Table of contents 3.14.5 Removing the hydraulic connectors ........3-71 3.14.6 Installing the hydraulic connectors .
Page 72 Table of contents 4th Generation Engines 8370 79492...
Page 73: Measuring Cylinder Liner Wear
3. Maintenance 3.1 Cylinder block 3.1.1 Measuring cylinder liner wear Procedure Using a micrometer, set the dial gauge to zero using a new cylinder liner indicating the initial dimension of the bore. See Technical data, Cylinder liners. Clean the inner surface of the cylinder liner thoroughly before measurement.
Page 74: Changing Camshaft Bushing (33-49 Engines)
3. Maintenance 3.1.4 Changing camshaft bushing (33-49 engines) Procedure Remove the bushing with an internal puller, for example SYKES 854. If the camshaft rear end plug is removed, the bushing can be forced out with a long drift. Clean the bushing location carefully.
Page 75 3. Maintenance Hole 98 engine Hole diameter 55.62 - 55.65 mm 55.42 - 55.45 mm 3 and 4 55.22 - 55.25 mm 55.42 - 55.45 mm 55.64 - 55.67 mm Fig. 5 66-84 engines:Press in new bushings (2 - 6). a) Look for the different outer diameters.
Page 76: Fitting Plug At Camshaft Rear End
Bushings are available even for other camshaft bearings which do not normally have bushings. Look for the position of the bushing oil holes. It is not necessary to ream the bushings after fitting. 33-49 engines Machining dimensions for the bushing locations are shown in the figure. Order numbers of the oversize camshaft bushings and hole diameters for the bushings are shown in the table.
Page 77: Fitting Plug At Camshaft Rear End (Oversize Bushings)
3. Maintenance 66-84 engines Order numbers of the oversize camshaft bushings Hole diameter Order number and hole diameters for the bushings are shown in 56.02 - 56.05 8368 66036 the table. Numbering begins from the front end of the engine. Installing places are the same as with the standard bushings.
Page 78 Fig. 11 Press tools 9101 66300 Dial gauge and holder 9025 79200 Fit a cylinder liner with a higher flange, if the cylinder liner height is too low. 33-74 engines Marking Order grooves pcs number 9.03+0.02 - (std.)
Page 79 Replace the cylinder liner, if the cylinder liner flange has any fault. Fit the O-rings. b) 33-74 engines: Fit the O-rings into the grooves in the cylinder liner. c) 84-98 engines: Fit the O-rings into the grooves in the cylinder block.
Page 80 3. Maintenance Press the cylinder liners into the cylinder block. The cylinder liners can be pressed to the position by hands. If not: • check the O-rings, • make sure that the O-rings are well lubricated, • check the contact surface in the cylinder block.
Page 81: Flywheel Housing
3. Maintenance 3.2 Flywheel housing 3.2.1 Fitting flywheel housing The flywheel housing is centred on the cylinder block by two tension pins. Even the flywheel housings which are delivered as spare parts have ready-made holes for the pins. Procedure Clean the sealing surfaces between the cylinder block and the flywheel housing.
Page 82 3. Maintenance Fit the seal. a) Fit the seal dry, not oiled. b) Put the seal carefully on the shaft. Make sure that the sealing lip is not damaged. c) Hit the seal into position with the fitting tool. Fig. 17 Fitting tool 9052 46300 Fitting tool 9104 52600 (84 and 98 engines) 3-14...
Page 83: Cylinder Head
3. Maintenance 3.3 Cylinder head 3.3.1 Removing cylinder head Procedure Disconnect current from the main switch. Clean the engine externally and drain the coolant. Disconnect the coolant hoses from the cylinder head and the thermostat housing. Remove the suction hoses between the turbocharger and the air filter and between the turbocharger and the inlet manifold.
Page 84 3. Maintenance Check for cracks and other damage. Check the flatness of the cylinder head against a straight edge. • An uneven or warped surface need to be surface ground. • The height of the cylinder head, after grinding, can not be less than 109.50 mm. •...
Page 85: Changing Valve Guides
3. Maintenance 3.3.4 Changing valve guides Procedure Press or knock out the old valve guides using drift 9120 85300. Clean the valve guide locations. Fig. 21 Drift 9120 85300 Lubricate the outside of the new valve guides. Fit the valve guides using drift 9120 85000. The drift makes sure the correct fitting height (13 mm over the spring face).
Page 86: Grinding Valves
3. Maintenance Turn the cylinder head over and knock out the valve and valve seat ring. Clean the valve seat ring location. Cool the new valve seat ring in liquid nitrogen until it stops bubbling, or alternatively put it in dry ice. Fit the valve seat ring with a drift.
Page 87: Fitting Valves
Change any bolts that are too long. Fit the valve tappets if removed. Check that the sealing surfaces are clean. 33-49 engines: Fit the cylinder head gasket and the cylinder head. 66-98 engines: Fit the cylinder head gaskets and the cylinder heads.
Page 88 3. Maintenance Tighten the cylinder head bolts increasing: a) First tighten to 80 Nm. b) Tighten by 90°. c) Tighten again by 90°. NOTE: After this the cylinder head does not need retightening. Adjust the valve clearances. Fig. 28 Tighten the exhaust manifold nuts to correct tightening torque.
Page 89: Valve Mechanism
Order Engine type of push rod number of push rod 245 - 246.3 8370 70119 33 - 74 286 - 287.3 8370 69014 84 -98 Fig. 30 Disassemble and clean the rocker arm mechanism. a) Check the shaft for wear.
Page 90: Changing Camshaft Or Camshaft Gear
Remove the rocker arm mechanism. Remove the radiator, cooling fan, alternator and belt. 33-49 engines: Remove the belt pulley, the crankshaft nut and the hub (with damper). 66-98 engines: Remove the belt pulley and damper. 66-98 engines: Loosen the crankshaft nut.
Page 91: Adjusting Valves
3. Maintenance Remove the timing gear casing cover (engine front cover). Lock the tappets up. Locking removes the risk of the tappets falling down when removing the camshaft, preventing the installation of the camshaft. Prevent the push rods from falling through. a) Lift two next to another push rods up, extending the push rods a little toward each other.
Page 92 3. Maintenance Adjustment instructions Exhaust valve Inlet valve (3 ) Injector 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. •...
Page 93 3. Maintenance • Rotate the crankshaft in the running direction so that valves in the 7th cylinder are rocking. Check valves in the 2nd cylinder. • Continue according to the order of injection: Injection order 1 - 2 - 4 - 6 - 7 - 5 - 3 Valves rock in cyl.
Page 94: Crankshaft
3. Maintenance 3.5 Crankshaft 3.5.1 Removing crankshaft Procedure Remove the oil sump. Disconnect the balancing unit lubricating oil pipe from the cylinder block. Unscrew the balancing unit fixing bolts. 44-49 engines: Remove the balancing unit and the lubricating oil pipe. Unscrew the lubricating oil pump pressure pipe fixing screws from the cylinder block.
Page 95: Changing Crankshaft Gears
3. Maintenance Measure the I.D. with a dial gauge which has been zeroed to the dimensions given in point With this method the indicator shows the actual bearing clearance. Measure at several points in case the worn bearing housing is not round. Grind the bearing journals on the crankshaft, if needed.
Page 96: Fitting Crankshaft
3. Maintenance 3.5.4 Fitting crankshaft NOTE: Bearing shells must never be reamed or machined in any other way. Do not file the sides of the bearing caps either. Procedure Clean the oilways, bearing shells and bearing locations. Check that the crankshaft is clean. Assemble the bearing with oil holes/groove (A) to the cylinder block and the bearing with no hole (B) to the bearing cap.
Page 97: Crankshaft Hub Piece
3. Maintenance 3.5.5 Crankshaft hub piece NOTE: 33-engines have speed sensor located on the crankshaft pulley. There fore these engines have fixed hub and pulley position with key and cotter pin. Fig. 44 Procedure Check hub piece condition, especially the sealing surface.
Page 98: Viscose Type Vibration Damper
3. Maintenance Check the condition of the rubber element. Change the damper, if • the rubber pieces have been loosened from the element • the rubber has been pressed to a depth of more than 3.5 mm • the outer circumference is slack •...
Page 99: Connecting Rods And Pistons
Make sure that the oil hole in the piston pin bushing coincides with the respective hole in the connecting rod by size and location. a) 33-74 engines: Cut and ream the piston pin bushing to obtain correct shape and diameter.
Page 100: Big-End Bearing
All the connecting rods in one engine should be of the same weight class, that is to say the greatest permissible weight difference is 20g. NOTE: Always change connecting rod screws, when opened. Weight class (33-74 engines) Letter (A) Weight...
Page 101: Changing Piston Rings
Measure the piston ring gap by pushing one piston ring at a time into the cylinder bore. 33-74 engines: The piston ring gap must not be larger than 1 mm on the 1st and 3rd piston rings and 1.5 mm on the 2nd piston ring.
Page 102: Checking Pistons
3. Maintenance Fit the piston rings on the piston using the piston ring pliers. NOTE: Be careful when handling the pistons to prevent any scratches. Make sure that the piston rings are fitted in the correct piston ring grooves and that "TOP", or the manufacturer indication, faces Check that the piston ring sliding surface is not damaged.
Page 103: Fitting Piston Pin
Make sure that the direction of the arrow on the piston shows forward. b) 33-74 engines: Use a piston ring strap or fitting tool 9201 85840. c) 84-98 engines: Use a piston ring strap or fitting tool 9231 06340.
Page 104: Counterbalance In 4 Cylinder Engines
3. Maintenance 3.7 Counterbalance in 4 cylinder engines 3.7.1 Removing and disassembling counterbalance unit Procedure Remove the oil sump. Disconnect the lubricating oil pipe of the counterbalance unit. Remove the counterbalance unit. Take care of any shims. Loosen the locking screws and press out the shafts in the direction of the locking screws. Remove the counterweights and thrust washers.
Page 105: Fitting Counterbalance Unit
3. Maintenance 3.7.3 Fitting counterbalance unit Procedure Fit the tension pins to the cylinder block. Turn the crankshaft and weights so that the markings correspond, and lift the unit into place. Tighten the screws to 60 Nm. Check that the tooth backlash between the crankshaft and counterweight is 0.1 - 0.3 mm.
Page 106: Flywheel
3. Maintenance 3.8 Flywheel 3.8.1 Changing starter ring gear on flywheel If the ring gear is worn, replace it with a new one. The ring gear cannot be turned around because its teeth are chamfered and hardened on the starter motor side.
Page 107: Timing Gear Assembly
Remove the hub from the crankshaft with puller. Take off the puller, open the nut and remove the hub. Fig. 64 33-49 engines: Crankshaft hub puller 9201 82390 66-98 engines: Crankshaft hub puller 9104 53300 4th Generation Engines 3-39...
Page 108: Fitting Timing Gear Casing
3. Maintenance Remove the camshaft speed sensor, hydraulic pump drive unit lubrication pipe and the drive unit (if installed) and remove the front cover. a) Look for the screws attaching to idler gear shaft. So called broad timing gear has similar screws on small idler gear shaft (arrowed in the picture).
Page 109 3. Maintenance d) Tighten nuts and bolts. Lubricate the camshaft bearings. Insert the camshaft into the cylinder block a) Release the push rods and tappets if the push rods and tappets have been hold in position. Fit the idler gear stud and the idler gear. a) Fit the idler gear stud.
Page 110: Fitting The Crankshaft Hub
NOTE: If the hub piece is worn out at the Fig. 68 sealing surface, a 3 mm spacer ring can be fitted under the crankshaft rear oil seal (33 - 33-84 engines: Drift 9103 94600 84 engines). 98 engine: Drift 9235 17520 NOTE: Do not use oil, the oil can run into the conical surfaces.
Page 111 3. Maintenance Install the hub in its place towards the crankshaft gear. NOTE: The conical sleeve must not be installed at this stage! Press the hub firmly against the gear and push cleaned and dry conical sleeve onto the crankshaft. Lubricate the hub nut thread, rear surface and outer surface (the surfaces affecting nut friction) with vaseline.
Page 112: Power Take-Off
3. Maintenance 3.9.4 Power take-off The engines use a transmission that can be equipped with a PTO run from the camshaft gear. The PTO can run e.g. a hydraulic pump. NOTE: Use molybdenite-sulphide (MoS2) ball bearing grease (NLGI 2) for the grooves of the hydraulic pump shaft and the coupling sleeve.
Page 113: Lubrication System
3. Maintenance 3.10 Lubrication system 3.10.1 Oil pressure regulating valve If the pressure of the engine lubricating oil is insufficient or varies, the oil level and then the oil pressure regulating valve need to be checked. Procedure Remove the cover and the spring with the valve plate.
Page 114: Assembling And Fitting Lubricating Oil Pump
3. Maintenance 3.10.3 Assembling and fitting lubricating oil pump Procedure Fit the gear wheels to the pump body. Fit the cover using a new gasket. Partly tighten the screws. Rotate the pump shaft and tap the side of the cover gently until it reaches the position in which the shaft rotates most freely.
Page 115 3. Maintenance Procedure Detach the valve from the engine and check its function. Fit a new valve if necessary. Fig. 77 Fit the nozzle pipe at a 90° angle to the center line of the crankshaft. Tighten the valve to 30 Nm. Make sure that the pipe does not touch the pistons or connecting rods when the engine is running.
Page 116: Fitting Oil Sump Gasket
Fig. 79 3.10.6 Lubricating oil cooler 33 - 74 engines Engines is fitted with an oil cooler, which is positioned in between the oil filter and the cylinder block. Procedure The engine coolant should be drained before removing the lubricating oil cooler.
Page 117: Fitting The Oil Cooler
3. Maintenance Procedure Open the coolant drain plug under the oil cooler and drain the coolant into a suitable container. Remove the coolant pipe going into the thermostat housing. Remove the turbo oil pipes and the oil pressure pipe. Remove the oil filter. Drain the oil into a container.
Page 118: Closed Crankcase Ventilation
84-98 engines: The CCV system has a centrifugal-type filtering, which is driven by the engine oil pressure. 33-74 engines: The CCV system has a filter that uses a small part of boost pressure for filtration boosting. 3.10.10.1 Installing the closed crankcase ventilation system components in 33 - 74 engines The Closed crankcase ventilation (CCV) filter is mounted on the rear end of inlet manifold.
Page 119 3. Maintenance Procedure Replace the mounting bracket O-ring and shaped gasket, if the CCV filter has been removed Fit the CCV system hoses. Make sure that there are no unnecessary bends or creases on the CCV system hoses. The hose line must be straightforwardly ascending as shown in the figure.
Page 120: Cooling System
3. Maintenance 3.11 Cooling system 3.11.1 Removing the thermostat Procedure Drain the cooling system so that the coolant level is below the thermostat. Disconnect the top hose from the water outlet cover. Remove the outlet cover. Remove the thermostat. Clean the sealing surfaces. 3.11.2 Testing the thermostat Procedure Lower the thermostat into a vessel of boiling water so that it does not touch the sides or bottom.
Page 121 3. Maintenance Remove the impeller from the shaft with puller 9101 93200 in 66- and 74-engines or according to the next instruction in other engines. Remove the impeller from the shaft. a) Remove the circlip from the pump body. b) Press the shaft together with the bearings pointing in the direction of the fan. Use a hydraulic press, for example.
Page 122 3. Maintenance Fit the belt pulley and tighten its attaching nut to a torque of 80 Nm (M12) or to 120 Nm (M16). Note in particular the left-hand thread of the belt pulley attaching screw. Fig. 88 Fig. 89 Fit the rear plate to the cylinder block using a new seal.
Page 123: Coolant Pumps With Heavy Duty Bearings
Lubricate the bearings with ball bearing grease. Fig. 93 AGCO Power recommends Isoflex Topas NB52 or NLGI 2 class grease, amount abt. 5 gr. 4th Generation Engines 3-55...
Page 124: Installing The Cylinder Head Connection Part
3. Maintenance b) Press the outer bearing into its place and fix the lock ring. Press the water seal into its place with drift 9201 97880. Press the impeller into its place while supporting the axle on the other end. See the mounting depth of the impeller from the Coolant pumps with standard bearings.
Page 125: Air Intake System
3. Maintenance 3.12 Air intake system 3.12.1 Checking the air cleaner The engine performance and length of service life depend to a great extent on the state of the air cleaner. A defective air cleaner allows impurities to pass through, which in time damages the turbocharger and the engine.
Page 126: Checking The Turbocharger
3. Maintenance Any loose objects or impurities can increase the back pressure for the exhaust gases from the turbine wheel. 3.12.3 Checking the turbocharger If a fault is suspected in the turbocharger, it can be located in the following way: Procedure Visually inspect the turbine and compressor wheels.
Page 127: Checking The Egr Actuator Voltages
3. Maintenance In order for the turbocharger to work satisfactorily, it is important that the engine oil is in good condition. Likewise, the oil should be to the correct quality specification. The air filter and oil filter should be serviced according to the Instruction Manual specification.
Page 128: Link Rod
3. Maintenance Pin Number Assignment Vbat CAN low CAN high Procedure Switch on the ECU. Measure the voltage between wire 3 from the ECU and ground 2. The voltage should be approximately 2V. Measure the voltage between wire 4 from the ECU and ground 2. The voltage should be approximately 3V.
Page 129: Fuel System
3. Maintenance 3.13 Fuel system 3.13.1 Bleeding the fuel system WARNING: Do not make any work at the common rail high pressure fuel system when the engine is running. Wait at least 30 seconds after stopping the engine .The first high pressure component has to be loosened slowly, so that the pressure inside the fuel system can adjust to ambient pressure.
Page 130: Inspecting Injectors
3. Maintenance Disconnect the fuel pressure sensor (1) from the fuel filter and connect the pressure gauge instead (the thread is M10x1). Run the engine at low idling speed for a while and compare the gauge reading with the prescribed value (4,5 - 5,5 bar). Fig.
Page 131: Fitting The Injectors (Crin3)
3. Maintenance Loosen the fastening screw holding the injector in place and the fastening nut holding the feeding pipe in place. a) Unscrew and remove the injector and the feeding pipe. b) Plug plastic covers into all the connection points. NOTE: The injector and the feeding pipe are calibrated as couple.
Page 132: Removing The Injectors (Cri2_16)
3. Maintenance Tighten the valve cover to correct torque value. 3.13.3.3 Removing the injectors (CRI2_16) Procedure Clean the high-pressure pipes, valve cover(s) and surroundings. Remove the injector fixing clips. Remove the overflow pipe. Remove the high-pressure pipes. Plug plastic covers into all the connection points.
Page 133: High-Pressure Pump
Remove the guide ring from the high- pressure pump. Remove the gear with the appropriate tool. Take the high-pressure pump to the Bosch Diesel agent or the service department of Fig. 109 AGCO power Inc. to be reconditioned. 4th Generation Engines 3-65 8370 79492...
Page 134: Fitting The High-Pressure Pump
3. Maintenance 3.13.4.2 Fitting the high-pressure pump Procedure Attach new O-rings to the sealing grooves of the high-pressure pump and the guide ring. If the front cover of the gear housing has not been removed, fix the gear to the shaft of the pump. Please note that the guide ring of the high-pressure pump has to be fixed to the pump flange before the gear is fixed.
Page 135 3. Maintenance Fig. 112 Pressure sensor Shut-off valve The rail is attached to the intake manifold. Turn the main switch to OFF position before handling the rail. Clean the rail and its surroundings carefully. Prevent fuel from leaking to the ground. Insert plugs where fuel connectors have been removed.
Page 136 3. Maintenance High Pressure Pipes It is recommended that high-pressure pipes are replaced every time they are removed. The torque for the high-pressure pipe connector is 30 Nm. 3-68 4th Generation Engines 8370 79492...
Page 137: Scr System
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.
Page 138: Removing The Supply Module
3. Maintenance NOx sensor NOx sensor includes a control unit and a separate sensor head. Mounting: 2 sensors on the exhaust line, before DOC catalytic converter and after the SCR catalytic converter. • Sensor head thread: M20x1,5 • Sensor head torque: 50 Nm •...
Page 139: Removing The Hydraulic Connectors
3. Maintenance Clean the supply module from any DEF leakage. Install wiring and tubing supports. 3.14.5 Removing the hydraulic connectors Removing of the supply module is important in order to replace the hydraulic connectors. By removing the supply module can be made sure that torque wrench can be used and that cleanliness can be guaranteed. Procedure Remove the supply module.
Page 140: Engine Control System
Change if necessary. c) Torque for the fixing screws is 30 Nm. Fig. 117 Fit the new control unit. 33-84 engines: Tighten the screws to 10 Nm in crosswise sequence (EDC17CV54). Note the earth wire under the upper right fastening screw.
Page 141: Wiring Sets
3. Maintenance 98 engine: Tighten the screws to 10 Nm in the order shown in the picture (EDC17CV41). Note the earth wire under the screw no 8. Connect the multipole connectors and attach the plastic cover. Turn the main switch to the ON position. Load the control unit (ECU) program using the service tool.
Page 142: Wiring Set For Appliance Connector
3. Maintenance Engine wiring NOTE: The wiring sets are delivered as complete sets; the connectors are not available as separate spare parts. 3.15.2.1 Wiring set for appliance connector Sensor wiring set Vehicle connector wiring set Adapter for connector NOTE: All engine versions do not have a wiring set for the vehicle connector.
Page 143: Sensors Of The Engine Control System
3. Maintenance 3.15.3 Sensors of the engine control system Boost Pressure/Air Temperature Sensor Ground Temperature signal +5 V Pressure signal Location: Boost pipe • Screw M5/3.3 Nm Fig. 122 Speed Sensor (camshaft) Ground Rpm signal Location: In timing gear housing •...
Page 144 3. Maintenance Speed Sensor (crankshaft) Ground Rpm signal Location: Cylinder block, left side • Screw M8/25 Nm • O-ring, order no. 6146 01524 Fig. 124 Oil pressure sensor Ground Pressure signal +5 V Location: Cylinder block, right side • Thread M10x1/25 Nm •...
Page 145 3. Maintenance Coolant and fuel temperature sensor Temperature signal / fuel signal +5 V Location: Cylinder head / coolant sensor and in fuel filter / fuel sensor • Thread M12x1.5/25 Nm • Seal ring, order no. 6158 81418 Fig. 126 Fuel transfer pressure sensor Ground Pressure signal...
Page 146 3. Maintenance 3-78 4th Generation Engines 8370 79492...
Page 147: Index
EGR ................piston pin bushing .......... 3-31 EGR cooler ............. 1-21 piston pin ............... 3-35 electronic control unit ..........3-72 piston rings ............3-33 engine control system ........... power take-off ............3-44 sensor ............3-75 service tool ............. 1-27 engine lifting ............1-8 engine serial number .............
Page 148 ............. 2-6 thermostat ............2-18 timing gears ........... 2-12 turbocharger ........... 2-19 valves ............... 2-5 terminal diagram ........... 2-33, 2-34 testing ..............3-52 thermostat ............ 1-18, 3-52 timing gear ............1-15 timing gear casing ........3-39, 3-40 torques ..............2-20 turbocharger ............

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