Agco Sisu Power Tier 4 5th Gen Final AWF Engines Service Manual

Workshop Service Manual Linnavuori December 2013 AGCO Power - Linnavuorentie 8-10 - FIN-37240 8370 79873 Linnavuori, Nokia, Finland English © AGCO 2013



Table of contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.2 To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.2.1 Engine type designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.2.2 Location of the engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.2.3 Marking of the engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1.2.4 Lifting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 1.3 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 2.1.1 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 2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 2.3 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 Removing cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.1.3 Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.1.4 Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.1.5 Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.1.6 Fitting plug at camshaft rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.1.7 Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.1.8 Fitting plug at camshaft rear end (oversize bushings) . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.1.9 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 3.10.4 Power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 3.10.5 Fan drive device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 3.11 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 3.11.1 Oil pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 3.11.2 Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 3.11.3 Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 3.11.4 Piston cooling nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 3.11.5 Fitting oil sump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 3.11.6 Lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 3.11.7 Removing lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 3.11.8 Fitting lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 3.11.9 Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 3.11.10 Oil sump capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 3.11.11 Closed crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 3.12 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 3.12.1 Coolant quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 3.12.2 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 3.12.3 Reconditioning coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 3.12.4 Installing the cylinder head connection part . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67 3.13 Air control system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69 3.13.1 Checking the air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69 3.13.2 Checking the inlet and exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69 3.13.3 Removing actuator of the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . 3-70 3.13.4 Fitting actuator of the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . 3-70 3.13.5 Removing the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70 3.13.6 Checking the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70 3.13.7 Fitting the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71 3.13.8 Removing the EGR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72 3.13.9 Fitting the EGR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72 3.13.10 Removing the EGR actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72 3.13.11 Fitting the EGR actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73 3.13.12 EGR link rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73 3.14 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74 3.14.1 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74 3.14.2 Technical data of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75 3.14.3 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 3.14.4 Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77 3.14.5 Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77 3.14.6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79 3.14.7 Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81 3.14.8 Fuel quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84 3.14.9 SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 3.15 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92 3.15.1 Service tool of the engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93 3.15.2 Electronic diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94 3.15.3 Changing the electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96 3.15.4 Wiring sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 1.2.1 Engine type designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.2.2 Location of the engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.2.3 Marking of the engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1.2.4 Lifting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 1.3 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 1-1 8370 79873

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. 1-3 8370 79873

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 1-5 8370 79873

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 1-7 1.2.3 Marking of the engine control unit 8370 79873

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] 8370 79873 33 300 44 345 49 345 66 515 74 525 84 665 98 790 [1] 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 33 44 49 66 74 84 98 type Number 3 4 4 6 6 6 7 of cylinders Displacem 3,3 4,4 4,9 6,6 7,4 8,4 9,8 ent (ltr) Cylinder 108 108 108 108 108 111 111 bore (mm) Stroke 120 120 134 120 134 145 145 (mm) Combusti Direct Direct Direct Direct Direct Direct Direct on injection injection injection injection injection injection injection Injection Automatic Automatic Automatic Automatic Automatic Automatic Automatic advance adjusted adjusted adjusted adjusted adjusted adjusted adjusted Valve 0,35 (cold 0,35 (cold 0,35 (cold 0,35 (cold 0,35 (cold 0,35 (cold 0,35 (cold clearance, or hot) or hot) or hot) or hot) or hot) or hot) or hot) intake and exhaust (mm) Direction Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise of rotation from the engine front 1-10 8370 79873

1. Introduction Fuel system Engine 33 44 49 66 74 84 98 type Fuel Bosch Bosch Bosch Bosch Bosch Bosch Bosch injection Common Common Common Common Common Common Common system Rail Rail Rail Rail Rail Rail Rail Fuel The fuel The fuel The fuel The fuel The fuel The fuel The fuel must be must be must be must be must be must be must be according according according according according according according to norm to norm to norm to norm to norm to norm to norm EN EN EN EN EN EN EN 590:2009, 590:2009, 590:2009, 590:2009, 590:2009, 590:2009, 590:2009, see Fuel see Fuel see Fuel see Fuel see Fuel see Fuel see Fuel quality quality quality quality quality quality quality requirem requirem requirem requirem requirem requirem requirem ents ents ents ents ents ents ents Injection 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 order -3 Injection Max. 1800 Max. 1800 Max. 2000 Max. 2000 Max. 2000 Max. 2000 Max. 2000 pressure bar bar bar bar bar bar bar Fuel filter: 10 µ 10 µ 10 µ 10 µ 10 µ 10 µ 10 µ Pre-filter Fuel filter: 5 µ 5 µ 5 µ 5 µ 5 µ 5 µ 5 µ Main filter Lubrication system 2,5 - 5 bar Lubrication system 1,5 bar Oil pressure in hot engine at running speed See Oil sump capacity Oil pressure at idle speed, min See Lubricating oil quality requirements Oil capacity Oil quality requirements 1-11 8370 79873

1. Introduction Cooling system Engine 33 44 49 66 74 84 98 type Number 1 1 1 1 / 2 2 2 2 of thermosta ts Opening ø 67 mm ø 67 mm ø 67 mm ø 54 mm ø 54 mm ø 54 mm ø 54 mm temperatu = 83 ° C = 83 ° C = 83 ° C = 79 ° C, = 79 ° C, = 79 ° C, = 79 ° C, re ø 67 mm ø 67 mm ø 67 mm ø 67 mm = 83 ° C = 83 ° C = 83 ° C = 83 ° C Coolant See See See See See See See quality Coolant Coolant Coolant Coolant Coolant Coolant Coolant requireme quality quality quality quality quality quality quality nts requirem requirem requirem requirem requirem requirem requirem ents ents\" ents\" ents\" ents\" ents\" ents\" 1.3.3 Cylinder block The cylinder block is the main body of the engine, to which other engine parts are attached. Wet and replaceable cylinder liners are supported at the middle, which reduces vibrations and directs coolant circulation mainly to the upper part of the liners. The seal between the 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 . The upper part is sealed by the cylinder head gasket. The camshaft is located in the cylinder block.The camshaft front bearing location is fitted with a separate bearing sleeve and the remaining bearing locations are machined directly in the cylinder block in 33-, 44- and 49-engines. There are separate bearing sleeves in all camshaft bearing locations and the drilling for the camshaft rear end is covered with a plug in the 66-, 74-, 84- and 98-engines. There are spaces on both sides of the rear main bearing for guide bearing shims (the crankshaft thrust bearings). 1.3.4 Flywheel housing The flywheel housing is fitted at the rear end of the cylinder block. The seal for the crankshaft rear end is placed in a bore in the housing. The starter motor fixing point is fitted in the flywheel housing. The lower face of the flywheel housing functions as a sealing surface for the oil sump gasket. This means that the lower face of the cylinder block must be level with the flywheel housing. When fitting the flywheel housing, its position is determined by tension pins. The flywheel housing is delivered according to the requirements set by the engine model and different flywheel housings can be mounted on all engine types. 1.3.5 Valve mechanism The valve mechanism is operated by the camshaft which is located in the cylinder block. The drive is transferred with the help of tappets and push rods. The camshaft gear wheel is fitted with a nut and guided with a key. Each bearing is lubricated by the force feed lubrication system through drilled oilways in the cylinder block. 1-12 8370 79873

1. Introduction 1.3.6 Cylinder head There is one cylinder head in the 33, 44 and 49 engines. 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). Every cylinder has four valves and in the middle of the valves there is a place for the injector. The injector is located vertically in the centre of the cylinder and in the middle of the combustion chamber. This ensures accurate and homogenous mixing of fuel and air and leads to clean and low emission combustion with good efficiency. Each cylinder has its own inlet and exhaust ports located on either side of the head. Every inlet valve has its own inlet port but there is only one exhaust port for every two of the cylinder’s exhaust valves. There are no water holes on the inlet side of the cylinder head. This eliminates the possibility of water entering the inlet air. Cylinder head bolts are high tensile bolts, which are tightened up to yield limit using the angle tightening method. Due to the large stretch, the tightening forces are kept constant during the whole lifetime and retightening is unnecessary. The injector and its side feeding pipe locations are machined directly into the cylinder head. The port for the side feeding pipe is located between the inlet ports. The inlet and exhaust valve guides are identical and can be interchanged. Inlet and exhaust valves are fitted with separate valve seat rings. 1.3.7 Crank mechanism The crankshaft is forged from chrome alloy special steel and is induction hardened at the bearing and sealing surfaces. This makes it possible to grind bearings four times and 98 engine two times without a new heat treatment. Gear wheels are located at the front end of the crankshaft. They are a press fit, and drive the idler wheel and oil pump. The belt pulley/vibration damper is fastened to the crankshaft with a cone joint. An oil deflector ring is fitted between the hub and gear wheel. The 98-engine has larger cone and an additional seal ring. The crankshaft is supported on the cylinder block by main bearings, which are placed on both sides of each cylinder. There is therefore one main bearing more than there are cylinders. The crankshaft thrust washers are placed in both sides of the rearmost main bearing. A flywheel, on which there is a press-fit starter ring gear, is fitted at the rear end of the crankshaft. The forged connecting rod has an I-cross-section. The bearing location at the bottom end of the connecting rod is fracture-split, and the bearing cup is secured by two special elongated screws. The upper part has a wedge-shaped bearing location, in which the piston pin bearing bushing is fitted with a press fit. The piston is made of a eutectic aluminium alloy. In the upper face of the piston there is a combustion chamber. The shape of the chamber is intended to maximise the mixture of air and fuel. The upper ring location is formed in a cast iron ring, which is cast in the piston. In addition, the piston is graphite-coated to ensure correct running-in. The piston has three rings. The upper molybdenum-coated ring has a wedge-shaped cross-section. The middle ring is tapered and it fits into its groove. The taper takes up the clearance. The oil control ring is spring-loaded and it has a two-stage, chromed scraping edge. Some four-cylinder engines are equipped with a balancer unit. The eccentric weights, which rotate at twice the engine speed, even out the vibration forces exerted by the movement of the pistons and the crank mechanism. 1.3.8 Timing gears 1-13 8370 79873

1. Introduction 1 Camshaft gear 2 Idler gear 3 High-pressure pump gear 4 Crankshaft gear 5 PTO gear 6 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. The idler gear is supported with a ball bearing on the shaft on the front face of the cylinder block. There are three main types of timing gear assembly: narrow without PTO, broad with light duty PTO and broad with heavy duty PTO. If the engine is equipped with light duty PTO, hydraulic pump is driven via a gear or a separate drive unit. In engines with heavy duty PTO, hydraulic pump or compressor is driven via a small idler gear. Fig. 5 1-14 8370 79873

1. Introduction 1.3.9 Lubrication system Fig. 6 Lubrication system (1) Oil pump (5) Turbocharger (2) Oil pressure regulating valve (6) Main oil gallery (3) Oil cooler (7) Piston cooling nozzle (4) Oil filter (8) Oil pressure sensor The engine has a pressure lubrication system with the gear oil pump fitted to the lowest level of the engine. 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 system by oil galleries or pipes. The lubrication of the gears in the gear housing, the upper end of the connecting 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. 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. NOTE: It is very important to use lubrication oil that corresponds to ambient temperatures (see Lubricating oil quality requirements). Always change the oil and oil filter according to the maintenance chart. 1-15 8370 79873

1. Introduction Oil pressure regulating valve The oil pressure regulating valve is located under the oil filter on the left side of the engine. The regulating 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 lubricating oil. At idling the pressure is 1,5 bar minimum. Fig. 7 Oil filter and oil cooler (1) Oil cooler 5 1 (2) Oil dipstick 2 (3) Oil pressure regulating valve 4 (4) Oil filter 3 (5) Coolant drain plug Fig. 8 8370 79873 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 engine 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. 1.3.10 Cooling system 1-16

1. Introduction (1) Coolant pump Fig. 9 (2) Thermostats (3) By-pass pipe (4) Radiator (5) Expansion tank (6) Oil cooler The coolant pump is attached to the front face of the cylinder block and the thermostat housing is mounted 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. NOTE: Never use only water as coolant but a mixture of 40 - 60 % of water and antifreeze. See Coolant quality requirements. Thermostats There are two separate thermostats (66, 74, 84 and 98 engines), of which one steers the by-pass of coolant liquid. The thermostats differ in type and opening temperature. When the coolant temperature is below the thermostat opening temperature, the coolant (A) circulates through the by-pass hole into the coolant pump. The smaller, single-acting thermostat (1) opens first (at 79°C), letting one part of the coolant (B) into the radiator. Following the load increase, the other thermostat (2) also opens (at 83°C). This is a double-acting type, which closes the by-pass hole when it opens and directs the coolant (C) into the radiator. There are no separate winter-type thermostats. Fig. 10 1.3.11 Air control system 1-17 8370 79873

1. Introduction 23 5 1 4 6 9 78 Fig. 11 (1) Air filter (6) Engine radiator (2) Low pressure turbocharger (7) Air to air intercooler (3) Interstage charge air cooler (ICAC) (8) Air intake throttle (4) Mass air flow (MAF) sensor (9) Intake manifold (5) High pressure turbocharger The air control system includes pre-filter (or cyclone, if installed), air filter, turbocharger(s), intercooler(s), air mass flow meter, throttle valve, intake manifold, exhaust manifold, EGR valve, EGR cooler 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. 1-18 8370 79873