AGCO Power 33 User manual

Workshop Service Manual
4th Generation Engines
AGCO POWER
Linnavuori
AGCO Power - Linnavuorentie 8-10 - FIN-37240
Linnavuori, Nokia, Finland
© AGCO 2014
November 2014
8370 79492
EAME
English

4th Generation Engines
1 Introduction ..............................................................1-1
1.1 Safety instructions .................................................1-3
1.2 To the user ........................................................1-5
1.2.1 Engine type designations ...........................................1-6
1.2.2 Location of the engine serial number ..................................1-7
1.2.3 Marking of the engine control unit ....................................1-8
1.2.4 Lifting the engine ................................................1-8
1.2.5 Starting the engine after major maintenance . . . . . . . . . . . ..................1-9
1.3 Engine construction ...............................................1-11
1.3.1 Engine construction overview ......................................1-11
1.3.2 Technical data ..................................................1-11
1.3.2.1 Principal dimensions and data ................................1-11
1.3.2.2 Fuel system .............................................1-11
1.3.2.3 Lubrication system ........................................1-12
1.3.2.4 Cooling system ..........................................1-12
1.3.2.5 SCR system technical data ..................................1-13
1.3.3 Cylinder block ..................................................1-13
1.3.4 Flywheel housing ...............................................1-13
1.3.5 Valve mechanism ...............................................1-13
1.3.6 Cylinder head ..................................................1-14
1.3.7 Crank mechanism ...............................................1-14
1.3.8 Timing gears ...................................................1-15
1.3.9 Lubrication system ..............................................1-16
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 .........................1-17
1.3.10 Cooling system ................................................1-18
1.3.10.1 Thermostat .............................................1-18
1.3.11 Air intake system ...............................................1-19
1.3.11.1 Cooled EGR system ......................................1-20
1.3.11.2 EGR cooler .............................................1-21
1.3.12 Fuel system ..................................................1-21
1.3.13 SCR-system ..................................................1-22
1.3.13.1 SCR system overview .....................................1-22
1.3.13.2 SCR system components and their functions ....................1-23
1.3.14 Engine control system ...........................................1-24
1.3.15 Service tool of the engine control system .............................1-27
2 Specifications ............................................................2-1
2.1 Technical data .....................................................2-3
2.1.1 Cylinder block ...................................................2-3
2.1.2 Cylinder liners ...................................................2-3
2.1.3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........2-4
2.1.4 Valves and rockers ...............................................2-5
2.1.5 Tappets and push rods ............................................2-6
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 ..................................................2-12
2.1.11 Connecting rod ................................................2-13
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2.1.12 Piston, rings and pin ............................................2-14
2.1.13 Lubrication system . . . . .........................................2-16
2.1.14 Oil pump . . . . . . . ..............................................2-17
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 tools ........................................2-27
2.3.7 Maintenance and troubleshooting tools ...............................2-27
2.4 Liquid quality requirements ........................................2-29
2.4.1 Lubricating oil quality requirements ..................................2-29
2.4.2 Coolant quality requirements .......................................2-29
2.4.3 Fuel quality requirements ..........................................2-30
2.5 Terminal diagram (3-6 cylinder engines) ............................2-33
2.6 Terminal diagram (7 cylinder engines) ..............................2-34
3 Maintenance .............................................................3-1
3.1 Cylinder block ..................................................... 3-5
3.1.1 Measuring cylinder liner wear ....................................... 3-5
3.1.2 Removing cylinder liner ............................................3-5
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) .............................3-6
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 ...............................................3-9
3.2 Flywheel housing .................................................3-13
3.2.1 Fitting flywheel housing ...........................................3-13
3.2.2 Changing crankshaft rear oil seal ....................................3-13
3.3 Cylinder head .....................................................3-15
3.3.1 Removing cylinder head ...........................................3-15
3.3.2 Removing valves ................................................3-15
3.3.3 Checking cylinder head ...........................................3-15
3.3.4 Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........3-17
3.3.5 Machining valve seat .............................................3-17
3.3.6 Changing valve seat rings .........................................3-17
3.3.7 Grinding valves .................................................3-18
3.3.8 Fitting valves ...................................................3-19
3.3.9 Fitting cylinder head .............................................3-19
3.4 Valve mechanism .................................................3-21
3.4.1 Reconditioning valve mechanism ....................................3-21
3.4.2 Changing camshaft or camshaft gear .................................3-22
3.4.3 Adjusting valves ................................................3-23
3.5 Crankshaft ........................................................3-26
3.5.1 Removing crankshaft .............................................3-26
3.5.2 Checking crankshaft .............................................3-26
3.5.3 Changing crankshaft gears .........................................3-27
3.5.4 Fitting crankshaft ................................................3-28
3.5.5 Crankshaft hub piece .............................................3-29
3.5.6 Checking element of the rubber damper (44-49 engines) ...................3-29
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3.5.7 Viscose type vibration damper ......................................3-30
3.6 Connecting rods and pistons .......................................3-31
3.6.1 Removing pistons together with connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.6.2 Changing connecting rod bearings ...................................3-31
3.6.2.1 Piston pin bushing ........................................3-31
3.6.2.2 Big-end bearing ..........................................3-32
3.6.3 Checking connecting rod . . . . . . . ...................................3-32
3.6.4 Changing piston rings ............................................3-33
3.6.5 Checking pistons ................................................3-34
3.6.6 Fitting piston pin ................................................3-35
3.6.7 Fitting piston together with connecting rod .............................3-35
3.7 Counterbalance in 4 cylinder engines ...............................3-36
3.7.1 Removing and disassembling counterbalance unit ........................3-36
3.7.2 Reconditioning counterbalance unit ..................................3-36
3.7.3 Fitting counterbalance unit .........................................3-37
3.7.4 Changing crankshaft gear rim .......................................3-37
3.8 Flywheel .........................................................3-38
3.8.1 Changing starter ring gear on flywheel ................................3-38
3.8.2 Fitting flywheel .................................................3-38
3.9 Timing gear assembly .............................................3-39
3.9.1 Removing timing gear casing .......................................3-39
3.9.2 Fitting timing gear casing . .........................................3-40
3.9.3 Fitting the crankshaft hub .........................................3-42
3.9.4 Power take-off .................................................3-44
3.9.5 Fan drive device ................................................3-44
3.10 Lubrication system ...............................................3-45
3.10.1 Oil pressure regulating valve ......................................3-45
3.10.2 Removing and dismantling lubricating oil pump .........................3-45
3.10.3 Assembling and fitting lubricating oil pump ............................3-46
3.10.4 Piston cooling nozzles ...........................................3-46
3.10.5 Fitting oil sump gasket ...........................................3-48
3.10.6 Lubricating oil cooler ............................................3-48
3.10.7 Removing the oil cooler ..........................................3-48
3.10.8 Fitting the oil cooler .............................................3-49
3.10.9 Oil sump capacity ..............................................3-49
3.10.10 Closed crankcase ventilation . . . . . . . . . . . . . . . . . . . . . ................3-50
3.10.10.1 Installing the closed crankcase ventilation system components in 33 -
74 engines ....................................................3-50
3.10.10.2 Installing the closed crankcase ventilation system components in 84
and 98 engines .................................................3-50
3.11 Cooling system ..................................................3-52
3.11.1 Removing the thermostat ........................................3-52
3.11.2 Testing the thermostat ..........................................3-52
3.11.3 Replacing the thermostat .........................................3-52
3.11.4 Reconditioning coolant pump ......................................3-52
3.11.4.1 Coolant pumps with standard bearings . . . . . . ...................3-52
3.11.4.2 Coolant pumps with heavy duty bearings .......................3-55
3.11.4.3 Coolant pumps with Flexonic belt ............................3-55
3.11.5 Installing the cylinder head connection part . . . . . . ......................3-56
3.12 Air intake system ................................................3-57
3.12.1 Checking the air cleaner ..........................................3-57
3.12.2 Checking the inlet and exhaust pipes ................................3-57
3.12.3 Checking the turbocharger ........................................3-58
3.12.4 Fitting the turbocharger ..........................................3-58
3.12.5 Checking the EGR actuator voltages ................................3-59
3.12.5.1 Link rod ...............................................3-60
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3.13 Fuel system .....................................................3-61
3.13.1 Bleeding the fuel system .........................................3-61
3.13.2 Measuring fuel feed pressure ......................................3-61
3.13.3 Inspecting injectors .............................................3-62
3.13.3.1 Removing the injectors (CRIN3) ..............................3-62
3.13.3.2 Fitting the injectors (CRIN3) .................................3-63
3.13.3.3 Removing the injectors (CRI2_16) ............................3-64
3.13.3.4 Fitting the injectors (CRI2_16) ...............................3-64
3.13.4 High-pressure pump ............................................3-65
3.13.4.1 Removing the high-pressure pump ...........................3-65
3.13.4.2 Fitting the high-pressure pump ..............................3-66
3.13.5 Rail .........................................................3-66
3.14 SCR system .....................................................3-69
3.14.1 SCR system maintenance ........................................3-69
3.14.2 Mounting of SCR system components ...............................3-69
3.14.3 Removing the supply module ......................................3-70
3.14.4 Installing the supply module .......................................3-70
3.14.5 Removing the hydraulic connectors .................................3-71
3.14.6 Installing the hydraulic connectors ..................................3-71
3.15 Engine control system ............................................3-72
3.15.1 Changing the electronic control unit .................................3-72
3.15.2 Wiring sets ...................................................3-73
3.15.2.1 Wiring set for appliance connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.15.2.2 Wiring set for intake air heater ...............................3-74
3.15.3 Sensors of the engine control system ................................3-75
4 Index .................................................................Index-1
Table of contents
4th Generation Engines
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1. Introduction
1.1 Safety instructions ......................................................1-3
1.2 To the user .............................................................1-5
1.2.1 Engine type designations ................................................1-6
1.2.2 Location of the engine serial number .......................................1-7
1.2.3 Marking of the engine control unit .........................................1-8
1.2.4 Lifting the engine .....................................................1-8
1.2.5 Starting the engine after major maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .......1-9
1.3 Engine construction ....................................................1-11
1.3.1 Engine construction overview ...........................................1-11
1.3.2 Technical data .......................................................1-11
1.3.2.1 Principal dimensions and data .....................................1-11
1.3.2.2 Fuel system ..................................................1-11
1.3.2.3 Lubrication system .............................................1-12
1.3.2.4 Cooling system ............................................... 1-12
1.3.2.5 SCR system technical data . . . . . . . . . . . . . . . . . ......................1-13
1.3.3 Cylinder block .......................................................1-13
1.3.4 Flywheel housing ....................................................1-13
1.3.5 Valve mechanism ....................................................1-13
1.3.6 Cylinder head . ......................................................1-14
1.3.7 Crank mechanism ....................................................1-14
1.3.8 Timing gears ........................................................1-15
1.3.9 Lubrication system ...................................................1-16
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 ..............................1-17
1.3.10 Cooling system .....................................................1-18
1.3.10.1 Thermostat . . ................................................1-18
1.3.11 Air intake system ....................................................1-19
1.3.11.1 Cooled EGR system ...........................................1-20
1.3.11.2 EGR cooler ..................................................1-21
1.3.12 Fuel system .......................................................1-21
1.3.13 SCR-system .......................................................1-22
1.3.13.1 SCR system overview ..........................................1-22
1.3.13.2 SCR system components and their functions .........................1-23
1.3.14 Engine control system ................................................1-24
1.3.15 Service tool of the engine control system . . . . . . . . . .........................1-27
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4th Generation Engines 1-1
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Table of contents
1-2 4th Generation Engines
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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.
• 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.
• 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.
• Do not remove the thermal protection of the exhaust manifold.
• 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 electronic control unit (ECU) main connector before starting work.
Important instructions
• Avoid unnecessary idling of the engine.
1. Introduction
4th Generation Engines 1-3
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• 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.
• 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. Introduction
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