AGCO Power 49 - Page 8

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1-2 4th Generation Engines

8370 79492

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Table of Contents3
Introduction7
Safety Instructions7
To the User7
Safety Instructions9
Engine Type Designations12
Location of the Engine Serial Number13
Marking of the Engine Control Unit14
Lifting the Engine14
Starting the Engine after Major Maintenance15
Engine Construction17
Engine Construction Overview17
Technical Data17
Principal Dimensions and Data17
Fuel System17
Lubrication System18
Cooling System18
SCR System Technical Data19
Cylinder Block19
Flywheel Housing19
Valve Mechanism19
Cylinder Head20
Crank Mechanism20
Timing Gears21
Lubrication System22
Oil Pressure Regulating Valve22
Oil Filter and Oil Cooler in 33-74 Engines23
Oil Filter and Oil Cooler in 84-98 Engines23
Oil Pressure Regulating Valve23
Cooling System24
Thermostat24
Air Intake System25
Cooled EGR System26
EGR Cooler27
Fuel System27
SCR-System28
SCR System Overview28
SCR System Components and Their Functions29
Engine Control System30
Service Tool of the Engine Control System33
Specifications35
Technical Data35
Cylinder Block37
Cylinder Liners37
Technical Data37
Cylinder Head38
Valves and Rockers39
Tappets and Push Rods40
Camshaft41
Crankshaft42
Flywheel46
Balancing Unit46
Timing Gears46
Connecting Rod47
Piston, Rings and Pin48
Lubrication System50
Oil Pump51
Thermostat52
Turbocharger53
Tightening Torques54
Special Tools56
Cylinder Block Tools56
Timing Gear and Flywheel Housing Tools57
Cylinder Head and Valve Mechanism Tools58
Crank Mechanism Tools59
Coolant Pump Tools60
Engine Control System Tools61
Maintenance and Troubleshooting Tools61
Liquid Quality Requirements63
Lubricating Oil Quality Requirements63
Coolant Quality Requirements63
Fuel Quality Requirements64
Terminal Diagram (3-6 Cylinder Engines)67
Terminal Diagram (7 Cylinder Engines)68
Maintenance69
Cylinder Block69
Measuring Cylinder Liner Wear73
Removing Cylinder Liner73
Checking Cylinder Block73
Changing Camshaft Bushing (33-49 Engines)74
Changing Camshaft Bushing (66-98 Engines)74
Fitting Plug at Camshaft Rear End76
Oversize Bushings for Camshaft76
Fitting Plug at Camshaft Rear End (Oversize Bushings)77
Fitting Cylinder Liner77
Flywheel Housing81
Fitting Flywheel Housing81
Changing Crankshaft Rear Oil Seal81
Cylinder Head83
Removing Cylinder Head83
Removing Valves83
Checking Cylinder Head83
Changing Valve Guides85
Machining Valve Seat85
Changing Valve Seat Rings85
Grinding Valves86
Fitting Valves87
Fitting Cylinder Head87
Valve Mechanism89
Reconditioning Valve Mechanism89
Changing Camshaft or Camshaft Gear90
Adjusting Valves91
Crankshaft94
Removing Crankshaft94
Checking Crankshaft94
Changing Crankshaft Gears95
Fitting Crankshaft96
Crankshaft Hub Piece97
Checking Element of the Rubber Damper (44-49 Engines)97
Viscose Type Vibration Damper98
Connecting Rods and Pistons99
Removing Pistons Together with Connecting Rods99
Changing Connecting Rod Bearings99
Piston Pin Bushing99
Big-End Bearing100
Checking Connecting Rod100
Changing Piston Rings101
Checking Pistons102
Fitting Piston Pin103
Fitting Piston Together with Connecting Rod103
Counterbalance in 4 Cylinder Engines104
Removing and Disassembling Counterbalance Unit104
Reconditioning Counterbalance Unit104
Fitting Counterbalance Unit105
Changing Crankshaft Gear Rim105
Flywheel106
Changing Starter Ring Gear on Flywheel106
Fitting Flywheel106
Timing Gear Assembly107
Removing Timing Gear Casing107
Fitting Timing Gear Casing108
Fitting the Crankshaft Hub110
Power Take-Off112
Fan Drive Device112
Lubrication System113
Oil Pressure Regulating Valve113
Removing and Dismantling Lubricating Oil Pump113
Assembling and Fitting Lubricating Oil Pump114
Piston Cooling Nozzles114
Fitting Oil Sump Gasket116
Lubricating Oil Cooler116
Removing the Oil Cooler116
Fitting the Oil Cooler117
Oil Sump Capacity117
Closed Crankcase Ventilation118
Installing the Closed Crankcase Ventilation System Components in 33 - 74 Engines118
Installing the Closed Crankcase Ventilation System Components in 84 and 98 Engines118
Cooling System120
Removing the Thermostat120
Testing the Thermostat120
Replacing the Thermostat120
Reconditioning Coolant Pump120
Coolant Pumps with Standard Bearings120
Coolant Pumps with Heavy Duty Bearings123
Coolant Pumps with Flexonic Belt123
Installing the Cylinder Head Connection Part124
Air Intake System125
Checking the Air Cleaner125
Checking the Inlet and Exhaust Pipes125
Checking the Turbocharger126
Fitting the Turbocharger126
Checking the EGR Actuator Voltages127
Link Rod128
Fuel System129
Bleeding the Fuel System129
Measuring Fuel Feed Pressure129
Inspecting Injectors130
Removing the Injectors (CRIN3)130
Fitting the Injectors (CRIN3)131
Removing the Injectors (CRI2_16)132
Fitting the Injectors (CRI2_16)132
High-Pressure Pump133
Removing the High-Pressure Pump133
Fitting the High-Pressure Pump134
Rail134
SCR System137
SCR System Maintenance137
Mounting of SCR System Components137
Removing the Supply Module138
Installing the Supply Module138
Removing the Hydraulic Connectors139
Installing the Hydraulic Connectors139
Engine Control System140
Changing the Electronic Control Unit140
Wiring Sets141
Wiring Set for Appliance Connector142
Wiring Set for Intake Air Heater142
Sensors of the Engine Control System143
Index147

AGCO Power 49 - Page 8

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