5th Generation AWF Engines
Operator's Manual
5th Generation AWF Engines
AGCO POWER
Linnavuori
AGCO Power - Linnavuorentie 8-10 - FIN-37240
Linnavuori, Nokia, Finland
© AGCO 2016
Original Operator's Manual
April 2016
8370 79929
English
Table of contents
5th Generation AWF Engines
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Engine type designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.2 Location of the engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.3 Marking of the electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.1 Principal dimensions and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.2 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.3 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.5 SCR system technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Engine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Air control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5.1 Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.2 2 stage turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.3 Cooling of inlet air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.4 Interstage charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.5 Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.6 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.6 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.8 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.8.1 Oil pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.8.2 Oil filter and oil cooler in 33-74 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.8.3 Oil filter and oil cooler in 84-98 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.9 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.9.1 Engine heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.10 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.11 SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.11.1 SCR system overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.11.2 SCR system components and their functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1 Operation and driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Daily pre-start check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4 Starting the engine in cold conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.1 Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5 Starting the engine with an auxiliary battery . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.6 Attention during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.7 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1 Periodical maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Maintenance charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.1 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.2 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Table of contents
3.2.3 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Maintenance to be made daily or at 10 hours intervals . . . . . . . . . . . . . . .
3.3.1 Check the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Check coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Check for leakages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Maintenance to be made weekly or at 100 hours intervals . . . . . . . . . . . .
3.4.1 Clean cooling system (from outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2 Examining the condition of the belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Maintenance to be made at 300 - 600 hours intervals . . . . . . . . . . . . . . . . .
3.5.1 Change engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.2 Oil sump capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.3 Change oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.4 Update engine software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.5 How to recognize an engine with hydraulic lash adjusters . . . . . . . . . . . . . . . . . . .
3.5.6 Valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.1 Adjusting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.2 Checking valve clearances in 44 engines . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.3 Checking valve clearances in 49 engines . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.4 Checking valve clearances in 66 engines . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.5 Checking valve clearances in 74 engines . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.6 Checking valve clearances in 84 engines . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.7 Checking valve clearances in 98 engine . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Maintenance in 800-1200 hours intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.1 Change fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.2 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.3 Drain fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Maintenance to be made at 4000 hours intervals . . . . . . . . . . . . . . . . . . . . .
3.7.1 Check turbocharger play and check that the intercooler cell is clean . . . . . . . . . . .
3.8 Maintenance to be made once a year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.1 SCR system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.2 Change SCR system main filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 Maintenance to be made every two years . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9.1 Change coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Additional maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.1 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.2 Before the cold season . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.4 Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.5 Coolant quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.6 Fuel quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.6.1 Biodiesel blends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.7 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.1 Engine control system fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2 Troubleshooting of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5th Generation AWF Engines
8370 79929
Table of contents
1. Introduction
1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Engine type designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.2 Location of the engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.3 Marking of the electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.1 Principal dimensions and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.2 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.3 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.5 SCR system technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Engine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Air control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5.1 Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.2 2 stage turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.3 Cooling of inlet air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.4 Interstage charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.5 Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5.6 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.6 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.8 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.8.1 Oil pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.8.2 Oil filter and oil cooler in 33-74 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.8.3 Oil filter and oil cooler in 84-98 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.9 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.9.1 Engine heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.10 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.11 SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.11.1 SCR system overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.11.2 SCR system components and their functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5th Generation AWF Engines
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Table of contents
6
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-B8C747FA-111A-41F2-8D6C-E05E16568B24
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!
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When you are operating the engine or working near it, use hearing protectors to avoid noise impacts.
If you start the engine indoors, be sure to have proper ventilation.
Never use aerosol type of starting aid! (Risk for explosion, personal injuries and engine damage!)
Start the engine only by using the starting switch in the cabin.
Stop the engine always before service or repair work.
Open fire, smoking and sparks should not be allowed near the fuel system and batteries. (Specially
when loading batteries, explosive.)
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 causes injuries when in contact with skin.
Avoid touching the exhaust manifold, turbocharger and the other hot parts of the engine.
Always disconnect the negative (-) battery cable when servicing or repairing the electric system.
Do not open high pressure pipe connectors of the fuel system when the engine is running. Wait atleast
30 sec. after stopping the engine. If the jet of high pressure fuel contacts your skin, fuel penetrates the
skin causing severe injuries. Get medical help immediately!
Keep the engine surfaces clean in order to avoid the risk of fire.
At temperatures on excess of 300°C, e.g. if the engine is burnt by a fire, the viton seals of the engine
(e.g. the undermost o-ring of the cylinder liner) produce very highly corrosive hydrofluoric acid. Do not
touch with bare hands, viton seals 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 alkaline solution. Put all removed material in
sealed plastic bags and deliver them to the point stated by the Authorities concerned.
NOTE: Never dispose of viton seals by burning!
• The fuel, lubricating oil and coolant cause irritation in long time skin contact.
• If for example welding or similar high current work is done for the application, it is recommended to
disconnect electronic control unit main connector and SCR supply module connector before working.
Important instructions
• Do not let oil and other liquids to the environment when servicing the engine. Take them to a proper
disposal point.
• Avoid unnecessary idling of the engine.
• All the gaskets of the engine are of non-asbestos material.
• Be careful when washing the engine with a high pressure washing machine. 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
the humidity removed, it is recommended to run the engine after washing
5th Generation AWF Engines
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7
1. Introduction
GUID-8400551D-C668-4488-A88C-91FA0C22512C
1.2 To the user
The purpose of this manual is to familiarise you with the use and maintenance of your AGCO POWER
engine and give you the basic technical data and settings relating to its construction. Before using the
engine carefully read the operating, service and safety instructions to ensure your engine runs in the most
economic way.
When contacting the Service Organisation, please state the engine type and the serial number.
5th Generation engines with aftertreatment system (AWF/ATF) meet EU97/68/EC Stage IV and EPA 40
CFR 1039 Tier 4 final emission requirements set by authorities.
The manufacturer guarantees that all engines of this type are equivalent to the engine that is officially
approved. This must be noticed especially when performing periodical maintenance, follow carefully the
maintenance schedule. Any adjusting and repair work for the injection system or the engine control unit
can only be made by a representative authorized by AGCO Power Inc. When performing any service or
repair work use only original AGCO Parts spare parts. Inadequate or delayed service and the use of other
than original AGCO Parts spare parts invalidates the responsibility of AGCO Power Inc. on the fulfilment of
the emission requirements.
We reserve the right to change the adjustment settings, equipment and also the service and repair
instructions of the engines without further notice. Unless otherwise stated, the instructions and settings
apply to all variants of 5th Generation engines.
The engine is guaranteed according to AGCO Power terms of warranty 8366 62489.
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.
Please fill your engine data here
Engine type
Engine serial number
Date of commissioning
GUID-F4C27C4A-A56F-4DF4-AEA0-90A813F806A8
1.2.1 Engine type designations
(1)
Basic type
74 = cylinder displacement, decilitres
A = aftertreatment system
(2)
Turbocharged engine
W = wastegate turbo
T = standard turbo
(3)
F = Tier 4 Final engine control technology
(4)
C = medium duty engine
G = generating set engine
GUID-942FD1B1-3EDB-4AE4-AE97-3613D4F84966-high.eps
M = marine engine
8
Fig. 1
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-F53FDD85-314E-4CB1-9D8A-01DD8BDD1DEA
1.2.2 Location of the engine serial number
The engine serial number is 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.
GUID-33B50DCE-F10B-4E45-9D0E-52339C1E90DE-high.eps
Fig. 2
5th Generation AWF Engines
8370 79929
9
1. Introduction
GUID-028C01BE-C489-4D20-9E15-A85640AF76C2
1.2.3 Marking of the electronic control unit
The specification of the application is indicated on
the type plate of the electronic control unit (ECU).
This specification must always be stated when
ordering an electronic 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.
GUID-8B183FF9-29D5-4D1D-9CB7-E6B211E3B92B-high.eps
Fig. 3
10
5th Generation AWF Engines
8370 79929
1. Introduction
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$*&23RZHU,QF
((0
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6HULDOQU
&&(
(&8
6HULDOQU
'DWH
GUID-B25F790E-91E0-4108-8E18-C9AA1E2A56A2-low.svg
Fig. 4
5th Generation AWF Engines
8370 79929
11
1. Introduction
1.3 Technical data
GUID-0AA60226-C24C-4AA7-A118-0F2E97CE50FC
1.3.1 Principal dimensions and data
Engine type
44
49
66
74
84
98
Number of
cylinders
4
4
6
6
6
7
Displacement 4,4
(ltr)
4,9
6,6
7,4
8,4
9,8
Cylinder bore 108
(mm)
108
108
108
111
111
Stroke (mm)
120
134
120
134
145
145
Fuel feed
Direct
injection
Direct
injection
Direct
injection
Direct
injection
Direct
injection
Direct
injection
Injection
advance
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
0,35 (cold or
hot)
0,35 (cold or
hot)
0,35 (cold or
hot)
0,35 (cold or
hot)
0,35 (cold or
hot)
Clockwise
Clockwise
Clockwise
Clockwise
Clockwise
0,35 (cold or
Valve
clearance,
hot)
intake and
exhaust (mm)
Direction of
rotation from
the engine
front
Clockwise
GUID-A8165595-0567-4D81-ADD3-712D11A4360C
1.3.2 Fuel system
Engine type
44
49
66
74
84
98
Fuel injection Bosch
Bosch
Bosch
Bosch
Bosch
Bosch
system
Common Rail Common Rail Common Rail Common Rail Common Rail Common Rail
Fuel
The fuel must
be according
to norm EN
590:2009 or
ASTM D975
1-D/2-D, see
the
information
for fuel
quality
requirements
The fuel must
be according
to norm EN
590:2009 or
ASTM D975
1-D/2-D, see
the
information
for fuel
quality
requirements
The fuel must
be according
to norm EN
590:2009 or
ASTM D975
1-D/2-D, see
the
information
for fuel
quality
requirements
The fuel must
be according
to norm EN
590:2009 or
ASTM D975
1-D/2-D, see
the
information
for fuel
quality
requirements
The fuel must
be according
to norm EN
590:2009 or
ASTM D975
1-D/2-D, see
the
information
for fuel
quality
requirements
The fuel must
be according
to norm EN
590:2009 or
ASTM D975
1-D/2-D, see
the
information
for fuel
quality
requirements
Injection
order
1-2-4-3
1-2-4-3
1-5-3-6-2-4
1-5-3-6-2-4
1-5-3-6-2-4
1-2-4-6-7-5-3
Maximum
injection
pressure
Max. 1800
bar
Max. 2000
bar
Max. 2000
bar
Max. 2000
bar
Max. 2000
bar
Max. 2000
bar
Fuel filter:
Pre-filter
10 μ
10 μ
10 μ
10 μ
10 μ
10 μ
Fuel filter:
Main filter
5μ
5μ
5μ
5μ
5μ
5μ
12
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-216487D0-F71C-465F-9E28-C9C0ABD0B9ED
1.3.3 Lubrication system
Lubrication system
Oil pressure in hot engine at running speed
ECU controls oil pressure automatically
Oil pressure at idle speed, min
ECU controls oil pressure automatically
Oil capacity
See information for oil sump capacity
Oil quality requirements
See information for lubrication oil quality
requirements
GUID-E65865F2-A1B5-460A-A9A6-1C8C5053C21E
1.3.4 Cooling system
Engine type
44
49
66
74
84
98
Number of
thermostats
1
1
2
2
2
2
Opening
temperature
ø 67 mm =
83 ° C
ø 67 mm =
83 ° C
ø 54 mm =
79 ° C, ø 67
mm = 83 ° C
ø 54 mm =
79 ° C, ø 67
mm = 83 ° C
ø 54 mm =
79 ° C, ø 67
mm = 83 ° C
ø 54 mm =
79 ° C, ø 67
mm = 83 ° C
See
information
for coolant
quality
requirements
See
information
for coolant
quality
requirements
See
information
for coolant
quality
requirements
See
information
for coolant
quality
requirements
See
information
for coolant
quality
requirements
Coolant
See
quality
information
requirements for coolant
quality
requirements
GUID-C3F4ED24-30F5-4AAE-8AD7-F0D0C30271BE
1.3.5 SCR system technical data
Principal data
SCR system
Bosch DENOXTRONIC 2.2+
98 AWF: Bosch DENOXTRONIC 2.2+ (12 kg / h)
Minimum operating temperature
-40 °C
Maximum DEF temperature
70 °C
Maximum SCR system temperature
80 °C
Dosing system
Reagent fluid type
DIN70070/ISO22241 certified DEF (Diesel Exhaust
Fluid), e.g. AdBlue
DEF consumption
Approximately 6-8% of fuel consumption[1]
Pre-filters
100 μ
Main filter
10 μ
[1]
DEF consumption may be higher, depending on the application and load profile of the engine.
5th Generation AWF Engines
8370 79929
13
1. Introduction
GUID-AF0CBF77-6EC3-46DC-951A-CBAD794E1D26
1.4 Engine overview
The AGCO POWER engines are water-cooled, turbocharged four-stroke diesel engines. The engines are
equipped with wet, changeable cylinder liners. The whole fuel system is located on the cold side of the
engine. The engines are equipped with an electric pre/post heater of intake air. The general arrangement of
the equipment is shown in the pictures.
GUID-D231A5E4-5F0E-4D88-ADA2-901FABCBD0B2-low.svg
Fig. 5 44 AWF / 49 AWF tractor engine
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
14
Turbocharger
Inlet air heater solenoid
Throttle valve
Inlet air heater
Rail
Hand pump
Oil filter and oil cooler
Speed sensor (crankshaft)
Oil pressure regulating valve
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Fuel pre-filter
Oil dipstick
Fuel main filter
Oil pressure sensor
High-pressure pump
Belt tightener
Coolant pump
Thermostats
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-6EF80E00-5396-4507-9577-5F19C6FECAD7-low.svg
Fig. 6 44 AWF / 49 AWF tractor engine
(1)
(2)
(3)
Electronic control unit (ECU)
CCV filter
Breather
5th Generation AWF Engines
8370 79929
(4)
(5)
Wastegate actuator
Starter
15
1. Introduction
GUID-1E6B41A0-5328-45C7-9FCC-9625FF356024-low.svg
Fig. 7 66 AWF / 74 AWF tractor engine
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
16
Turbocharger
Throttle valve
Inlet air heater
Inlet air heater solenoid
Rail
Hand pump
Oil filter and oil cooler
Speed sensor (crankshaft)
Oil pressure regulating valve
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Fuel pre-filter
Fuel main filter
Electronic control unit (ECU)
Oil dipstick
Oil pressure sensor
High-pressure pump
Belt tightener
Coolant pump
Thermostats
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-D3D2D579-0000-4EB8-9886-14114944AD5D-low.svg
Fig. 8 66 AWF / 74 AWF tractor engine
(1)
(2)
Breather
CCV filter
5th Generation AWF Engines
8370 79929
(3)
(4)
Wastegate actuator
Starter
17
1. Introduction
1
2
3
4
15
5
6
7
8
14
9
10
11
12
13
GUID-9091E957-E3BA-4EC9-8F36-525FE53B0F28-high.eps
Fig. 9 AGCO POWER 74 AWF combine engine
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
18
Turbocharger
Breather
Inlet air heater
Inlet air heater solenoid
CCV filter
Rail
Hand pump
Oil filter and oil cooler
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Speed sensor (crankshaft)
Oil pressure regulating valve
Fuel filters
Electronic control unit (ECU)
High pressure pump
Coolant pump
Oil filler plug
5th Generation AWF Engines
8370 79929
1. Introduction
2
1
3
7
4
6
5
GUID-C1B590B9-1937-4597-8018-620B2402A47E-high.eps
Fig. 10 AGCO POWER 74 AWF combine engine
(1)
(2)
(3)
(4)
Wastegate actuator
Throttle valve
Thermostats
Belt tightener
5th Generation AWF Engines
8370 79929
(5)
(6)
(7)
Alternator
Oil dipstick
Starter
19
1. Introduction
1
2
3
4
5
6
7
8
13
9
10
11
12
GUID-3A03B696-2F82-466B-B51C-B1FDF117793D-high.eps
Fig. 11 AGCO POWER 84 AWF combine engine
(1)
(2)
(3)
(4)
(5)
(6)
(7)
20
Low-pressure turbocharger
High-pressure turbocharger
Wastegate actuator
Oil filler plug
Inlet air heater solenoid
Rail
Hand pump
(8)
(9)
(10)
(11)
(12)
(13)
CCV filter
Speed sensor (crankshaft)
Fuel filters
Electronic control unit (ECU)
High pressure pump
Coolant pump
5th Generation AWF Engines
8370 79929
1. Introduction
2
1
3
15
14
4
13
12
5
6
11
10
9
8
7
GUID-27CAD051-1254-4340-9147-BB9CB919E195-high.eps
Fig. 12 AGCO POWER 84 AWF combine engine
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Breather
Inlet air heater
Throttle valve
Thermostats
Belt tightener
Alternator
Oil pressure regulating valve
Oil dipstick
5th Generation AWF Engines
8370 79929
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Oil filter and oil cooler
Interstage charge air cooler (ICAC)
Starter
EGR cooler
EGR valve
Mass air flow (MAF) sensor
EGR actuator
21
1. Introduction
GUID-7A7BC71C-D9A0-4CCE-B50D-5AE7C4E8B3C0
1.5 Air control system
GUID-BC48E994-5024-4980-BA68-4A83F6FE652A-high.eps
Fig. 13
(1)
(2)
(3)
(4)
(5)
Air filter
Low-pressure turbocharger
Interstage charge air cooler (ICAC)
Mass air flow (MAF) sensor
High-pressure turbocharger
(6)
(7)
(8)
(9)
Engine radiator
Air to air intercooler
Throttle valve
Intake manifold
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.
22
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-E60F39BF-CFDC-4474-B1D8-5F84C8092288
1.5.1 Turbocharging
The turbocharger is a turbo-compressor driven by exhaust gas. The compact design of the turbocharger is
fast to react even at low engine speeds. The turbocharger is lubricated and cooled by the lubrication
system of the engine. Boost pressure is controlled by a wastegate. Traditional wastegate is replaced with a
wastegate operated by actuator controlled by the electronic control unit (ECU). ECU-controlled wastegate
is used to control acceleration smoke and exhaust temperatures.
GUID-7998F62C-182F-45E3-824D-5F255C92C139
1.5.2 2 stage turbocharging
84 and 98 engines
The turbocharger is a turbo-compressor driven by exhaust gas. The compact design of the turbocharger is
fast to react even at low engine speeds. The turbocharger is lubricated and cooled by the lubrication
system of the engine. The engine has 2 stage turbocharging. Benefits from 2 stage turbocharging are
increased low speed torque, better specific fuel consumption and decreased exhaust temperature. The 2
stage charging uses two turbochargers: Bigger low pressure turbocharger raises pressure to 1 - 1,5 bar
(relative), Smaller high pressure turbocharger has boost pressure of 2,1 - 3 bar (relative). Boost pressure is
controlled by a wastegate. Traditional wastegate is replaced with a wastegate operated by actuator
controlled by the electronic control unit (ECU). ECU-controlled Wastegate is used to control acceleration
smoke and exhaust temperatures.
GUID-0BFDFEFE-0CD4-41D1-BD6B-79A1892C44AE
1.5.3 Cooling of inlet air
The compressed air from turbocharger is cooled on the air-to-air basis. The air coming from the
turbocharger has a temperature of abt. 150°C which is cooled by the cooling air of the engine. The cooling
of the compressed air stabilises the combustion, irrespective of the temperature, and minimises the
thermal and mechanical load of the engine thus lowering nitric oxides (NOx) and particles (PT).
GUID-5F431C3B-B387-4365-8FEC-3FE0A9C72858
1.5.4 Interstage charge air cooling
In 2 stage turbocharged engines the charge air is cooled between the turbochargers to increase the
efficiency and reliability. The charge air is cooled by engine coolant in the Interstage charge air cooling
(ICAC). The compressed air from high-pressure turbocharger is cooled on the air-to-air basis. The air
coming from the turbocharger has a temperature of abt. 150°C which is cooled by the cooling air of the
engine. The cooling of the compressed air stabilises the combustion, irrespective of the temperature, and
minimises the thermal and mechanical load of the engine thus lowering nitric oxides (NOx) and particles
(PT).
GUID-40A6A1CE-0DC4-4DB2-9990-4D0EBA67F547
1.5.5 Throttle valve
The throttle valve is used to manage temperatures
in the exhaust gas aftertreatment system. The
throttle valve controls Air/Fuel -ratio to speed up
engine warming, to increase exhaust temperatures
at low loads and to decrease exhaust
temperatures at high loads. The throttle valve is
controlled by the electronic control unit (ECU) with
the PWM current (pulse width modulation). The
throttle valve has an integrated actuator.
GUID-7AE54A5B-C71F-472C-BFFE-803E43467F17-high.eps
Fig. 14
5th Generation AWF Engines
8370 79929
23
1. Introduction
GUID-F3DA76A1-D584-4088-BC3B-C109BDDADFD3
1.5.6 Exhaust gas recirculation system
GUID-73CB2BD5-E246-4D62-9BD3-730AD1919E6B-high.eps
Fig. 15
(1)
(2)
(3)
(4)
Intake manifold
Exhaust manifold
EGR actuator (cooled)
EGR valve
(5)
(6)
(7)
EGR cooler
Thermostat
Coolant pump
The cooled exhaust gas recirculation system (EGR) used on AGCO POWER engines is controlled by
electronic engine control unit (ECU) and EGR actuator. Part of exhaust gases is led from exhaust manifold
through EGR valve to EGR cooler where they are cooled with engine coolant. The cooled exhaust gas is
mixed with fresh intake air in intake manifold before it flows to combustion chamber. The cooled EGR
system decreases the temperature in combustion chamber, which in turn results as lower nitrogen oxide
(NOx) emissions. All EGR engines have air mass flow meter. Its main functions are to measure EGR/fresh
air ratio for EGR control and to enable accurate DEF dosing to the catalyst.
24
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-1249CA3E-7BAC-4915-8390-62D64ECD1E96
1.6 Fuel system
The engine is equipped with common rail system which is controlled by electronic control unit (ECU).
9
10
8
1
2
11
3
5
4
7
6
11
GUID-9279C989-4B1E-40EB-A8F9-AA2CEC1A1DAB-high.eps
Fig. 16
(1)
(2)
(3)
(4)
(5)
(6)
Fuel inlet
Hand pump
Pre-filter
Fuel filter
Feed pressure sensor
Temperature sensor
(7)
(8)
(9)
(10)
(11)
High pressure pump
Rail
Pressure control valve
Injector
Pressure sensor
Fuel is drawn from the tank via the pre-filter, through the main fuel filter to the high pressure pump. From
the high pressure pump, fuel is pumped up into the rail. This high pressurized fuel is lying in a high
pressure pipe where it is controlled and injected through electronic injectors that are controlled by ECU.
The injection is optimized in terms of emissions, efficiency and operation noise and takes place in four
steps (maximum). Excess fuel returns from the injectors and pressure regulating valves of the high
pressure pump and rail back to the fuel tank. The overflow pipe from the filter helps the bleeding of the
5th Generation AWF Engines
8370 79929
25
1. Introduction
system. The fuel is diesel fuel according to the norm EN 590:2009 or ASTM D975 and it must be clean and
free from water after storage (see the information for fuel quality requirements).
NOTE:
Use of anti-freeze solution is not allowed and not useful at all!
Water is removed from the system by draining the water trap periodically and by cleaning the fuel tank
before frost season (see the information for before cold season).
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. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
26
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-4FFD8E5D-5FF2-43E1-822B-8EE1835171F1
1.7 Engine control system
15
14
13
9
10
11
16
12
17
18
8
7
21
19
20
6
5
4
1
2
3
GUID-9EBC42DA-9599-4029-8A9A-67FB2AEAC1EB-high.eps
Fig. 17 Parts of engine control system
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Electronic control unit (ECU)
Oil pressure sensor
Fuel pressure sensor
Magnetic proportional (M-PROP) valve
Speed sensor (camshaft)
Coolant temperature sensor
Rail pressure sensor
5th Generation AWF Engines
8370 79929
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Injector wiring
Wastegate actuator
Throttle valve
Boost pressure sensor
Inlet air heater
Inlet air temperature sensor
Mass air flow (MAF) sensor
27
1. Introduction
(15)
(16)
(17)
(18)
EGR actuator (84 and 98 engines)
Inlet air heater solenoid
Fuse, inlet air heater
Pressure control valve (PCV)
(19) Speed sensor (crankshaft)
(20) Fuel temperature sensor
(21) Fuel pressure sensor
The basic function of the electric control of the engine is continuous adjustment and measuring of the load,
quantity of fuel and rotating speed. Other additional functions are for example cold start automatics, engine
protecting automatics and SCR system control. The central unit of the electric control receives continuous
signals from sensors that measure different functions in the engine like rotating speed, oil pressure, boost
pressure, coolant and fuel temperature. The control unit receives the relevant information about the engine
load need from the transmission or cabin through the CAN bus. The electronic control unit (ECU) makes it
also possible to have a wide diagnostics through error codes.
28
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-01E4379A-C3F0-44E6-8641-B0547255A396
1.8 Lubrication system
GUID-DE07FA30-84E3-4141-831D-F665E81EC6C9-low.jpg
Fig. 18 Lubrication system
(1)
(2)
(3)
(4)
Oil pump
Oil pressure regulating valve
Oil cooler
Oil filter
(5)
(6)
(7)
(8)
Turbocharger
Main oil gallery
Piston cooling nozzle
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.
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.
NOTE: It is very important to use lubrication oil that corresponds to ambient temperatures (see information
for oil quality requirements). Always change the oil and oil filter according to the maintenance chart.
5th Generation AWF Engines
8370 79929
29
1. Introduction
GUID-F8E7B7EA-F1F7-4C33-A8E0-F213F5DFD1B6
1.8.1 Oil pressure regulating valve
The oil pressure regulating valve is close to the oil
filter. The oil pressure 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.
GUID-C57121F2-CCC1-4E9C-8B0F-838805A69B4B-high.eps
Fig. 19
GUID-40945B40-3DE6-4DAD-91C7-CDC15E8183E3
1.8.2 Oil filter and oil cooler in 33-74 engines
(1)
(2)
(3)
(4)
Oil cooler
Oil filter
Coolant drain plug
Oil pressure regulating valve
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 oil filter.
The engine has an oil cooler, which is between the
cylinder block and the oil filter. All oil that circulates
through the filter also goes through the oil cooler
and is cooled by the engine coolant circulating in
the oil cooler.
GUID-9821A6A1-7FA7-4F20-BE56-D45E6AC7C664-high.eps
Fig. 20
GUID-140A98CE-B380-4000-86FB-8ECA1A6CEE94
1.8.3 Oil filter and oil cooler in 84-98 engines
(1)
(2)
(3)
(4)
(5)
Oil cooler
Oil dipstick
Oil pressure regulating valve
Oil filter
Coolant drain plug
The oil filter is of main flow type. It has a
replaceable cartridge mounted on the right 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 oil filter.
1
2
5
The engine is equipped with a plate type oil cooler,
that is situated on the right side of the engine
above the oil filter. All oil that circulates through
the filter also goes through the oil cooler and is
cooled by the engine coolant circulating in the oil
cooler. The oil cooler is of main flow type.
3
4
GUID-33FE3E84-FEA7-4843-BB01-5E801803C688-high.eps
Fig. 21
30
5th Generation AWF Engines
8370 79929
1. Introduction
GUID-29B13530-E4D8-4771-B7ED-C4DE6EABEA28
1.9 Cooling system
(1)
(2)
(3)
(4)
(5)
(6)
Coolant pump
Thermostats
By-pass pipe
Radiator
Expansion tank
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
the information for coolant quality requirements.
GUID-C4115F90-FB09-4EEF-A669-3C1793F6F2ED-high.eps
Fig. 22
GUID-5C8620B0-FFF1-41EE-B431-7672E2FBD92A-high.eps
Fig. 23
GUID-BEBCC470-AB61-42FB-8936-819A511D013C
1.9.1 Engine heater
Most engines of this generation have a coolant pre-heater as standard equipment. It is installed on the left
side of the cylinder block on the same side as the fuel filters (fitting hole ∅ 40 mm). Connecting wires and
mains supply cables are also available in different lengths to help connecting the heater.
Install the coolant pre-heater according to the instructions of the manufacturer.
5th Generation AWF Engines
8370 79929
31
1. Introduction
GUID-D3F2D117-1C59-44EE-8B0A-22E3F50D7C5E
1.10 Electrical system
The electrical system is alternatively 12 or 24 Volts. In the 24 V system some of the electrical equipment in
the engine is using 12 Volts via a built-in voltage reducer.
Also the SCR system of the engines operates accordingly at 12 or 24 V nominal voltage. In 24 V systems
can be used either 24 V NOx sensor or 12 V NOx sensor, which needs to be equipped with a voltage
reducer. In order to avoid any damage to the electrical components, do not alter the electrical connections
of the SCR system.
32
5th Generation AWF Engines
8370 79929
1. Introduction
1.11 SCR system
GUID-4B8DD032-A898-42D0-AE3E-2200FDA53C55
1.11.1 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. The heat of exhaust gases converts DEF to ammonia and carbon dioxide. After this the
ammonia reacts with nitrogen oxides in catalyst reducing them to harmless nitrogen gas and water steam.
The DEF consumption is approximately 6 - 8 % of the fuel consumption. The DEF tank and pipes are
heated so system works also in low temperatures. If DEF freezes, it is automatically defrosted when the
engine is started. The congealing point of DEF with 32,5 % urea concentration is -11 °C.
CAUTION:
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used as a reducing
agent. If urea quality sensor detects a problem related to urea quality, it will alert the
engine control system via CAN message thus causing the engine to run under degraded
mode.
See instructions of the machine for details of filling up, location and capacity of the DEF tank.
CAUTION:
The storage of DEF must be done under 30°C, avoiding direct sunlight.
CAUTION:
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used as a reducing
agent. Diluting of DEF or mixing it with other substances is not allowed, it may damage
the catalyst!
CAUTION:
Even small amounts of diesel fuel in DEF tank may damage the gaskets of the SCR
system!
CAUTION:
Be careful when handling DEF. DEF is aggressive to some materials and corrosive to some
metals. DEF becomes crystalline when in contact with air. In case of a spillage rinse with
plenty of water and dry with a clean cloth.
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.
NOTE: This manual only provides general information relating to SCR system. All service and repair work
should only be performed by someone with special training and the necessary special tools and gauges. All
servicing and repair work relating to the SCR system requires particular care and cleanliness!
5th Generation AWF Engines
8370 79929
33
1. Introduction
GUID-7941E341-3EE0-4E52-9093-49DA956A4D08
1.11.2 SCR system components and their functions
GUID-6807B516-08F8-40F2-9CD3-4866E6C92059-low.jpg
Fig. 24
The exhaust gas aftertreatment system used is Bosch DENOXTRONIC2.2 (DNOX2.2). DNOX2.2 uses SCR
(Selective catalyst reduction) technology in order to reduce the exhaust emissions from the engine.
AGCO POWER SCR system consists of engine control system and DNOX2.2 SCR system. These two
systems are connected together via CAN bus.
See instructions of the appliance for location and instructions for removing and installing the SCR system
components.
Supply module
Supply Module (SM) transfers NOx reductant (DEF) from tank and pressurizes it. It contains also filters for
reductant (prefilter and mainfilter).
Dosing module
Dosing module (DM) is installed in the exhaust pipe between turbocharger and SCR catalyst. DM contains
an electrically operated, ECU controlled solenoid valve, which will inject the required amount of DEF
through the DM nozzle. DEF amount is calculated by EEM4 for optimal reduction of NOx.
Sensors
DNOX2.2 system includes several sensors:
•
•
•
•
34
NOx sensors
Exhaust temperature sensors
DEF tank level sensor
Temperature sensors: DEF tank, Supply Module internal
5th Generation AWF Engines
8370 79929
Table of contents
2. Operation
2.1
2.2
2.3
2.4
Operation and driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Daily pre-start check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Starting the engine in cold conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.1 Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5 Starting the engine with an auxiliary battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.6 Attention during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.7 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5th Generation AWF Engines
8370 79929
35
Table of contents
36
5th Generation AWF Engines
8370 79929
2. Operation
GUID-111AB8AF-B149-4E35-96B7-68E2AE3B3DC3
2.1 Operation and driving
Before using the engine, carefully read all safety instructions.
When starting and controlling the engine, follow the instructions made by the manufacturer of the
machine.
5th Generation AWF Engines
8370 79929
37
2. Operation
GUID-EF24BD2E-31C7-423D-BF47-E350292251CF
2.2 Daily pre-start check
Before starting the engine
•
•
•
•
•
•
check fuel quantity
check DEF quantity
NOTE: See instructions of the machine for
information about low level warning system,
indicated by the DEF level warning symbol.
check lubrication oil level
check coolant level
check that the lubrication oil system and
coolant system of the engine are not leaking
clean the cyclone of the air filter
Fig. 1 DEF level warning symbol
38
5th Generation AWF Engines
8370 79929
2. Operation
GUID-9D9D59C6-C744-4B9D-AD17-94DB51E1D3A4
2.3 Starting the engine
Before starting the procedure
See starting instructions of the machine.
NOTE:
Ensure that the SCR system is able to start after standing unused for long time (over 6 months) by
performing a normal afterrun procedure and keeping the system closed, also the fuel tank ventilation, if
possible. Any other procedure (drying with compressed air, flushing) could damage the SCR system and
has to be avoided.
When re-starting, it is recommended to change the Diesel Exhaust Fluid (DEF) because of aging effects
(condensed water could change the concentration of the DEF and thus affect the emissions). It is
recommended to change the main filter element (see the information for SCR system main-filter change)
before starting the engine.
Procedure
• Turn the ignition key to position current on. Wait until signal light of intake air heater is off.
• Start the engine and adjust the speed with the speed lever to prevent the engine from racing.
• Watch the oil pressure.
To ensure sufficient lubrication, the pressure gauge has to be within normal range in 3 - 4 seconds after
starting. This is particularly important for the lubrication of the turbocharger.
A cold engine might have, for a short period, an oil pressure of even 7 - 9 bar, depending on oil quality
and temperature.
• Always accelerate the engine at an even rate, never by racing.
5th Generation AWF Engines
8370 79929
39
2. Operation
GUID-080D8A56-6288-4BEA-BC87-6CDBCD2CDDD6
2.4 Starting the engine in cold conditions
Before starting the procedure
DANGER:
Never use starting aerosol to start the engine! The intake air heater causes an explosion
in the intake manifold. This can result in serious damage to the engine and personal
injuries. Use of starting aerosol invalidates the engine warranty.
See starting instructions of the machine. See also
actions before winter.
Engine is equipped with an electric pre / post
heater of the intake air. The post heating operates
automatically.
The DEF tank and pipes are heated so the SCR
system works also at low temperatures. If DEF
freezes, it is defrosted when the engine is started.
The congealing point of DEF is -11°C.
GUID-1BF7F2CE-5CF3-4E8D-A01E-DF8108CD0F92-low.jpg
Fig. 2
Procedure
• Make sure the battery is sufficiently charged.
• Release the engine of all extra load (move the gear to neutral position, depress the clutch pedal, do not
turn the steering wheel etc.).
• Keep the gas pedal on idling position. Heat the time when the alarm light is on and start the engine. If
the engine doesn’t start during ten seconds, stop the starting and heat again. (The preheating of intake
air doesn’t work during the starting.) When the engine starts, you can support it with the starter until
the engine runs complete.
• Watch the oil pressure.
• Do not race the cold engine because the lubrication is not sufficient while the oil is cold.
GUID-88A35E2E-D0DD-46D4-B4FD-2BEF400DB46B
2.4.1 Warming up the engine
Since the engine wear is greatest when the engine is running cold, warm up the engine quickly with a light
load for a couple of minutes after starting.
When the engine temperature is below 50°C:
• Engine must not be loaded heavily
• Rotation speed exceeding 1700 rpm must be avoided
40
5th Generation AWF Engines
8370 79929
2. Operation
GUID-7B06A619-A36C-467A-AB8A-5DB51398A8B6
2.5 Starting the engine with an auxiliary battery
DANGER:
Risk of explosion! Never connect the cable to the negative pole of the discharged battery.
•
•
•
•
Connecting the battery cables to the wrong poles will damage the systems.
Never open the charging circuit while the engine is running.
Disconnect the alternator and battery wires before undertaking any electrical welding.
Disconnect the battery wires before charging the battery.
Procedure
1.
Check that the auxiliary battery has the same voltage as the standard battery.
2.
Open the battery plugs to avoid risk of explosion.
3.
Connect the positive pole (+) of the auxiliary battery to the positive pole of the starter or to the
positive pole of the discharged battery.
4.
Connect the negative pole (-) of the auxiliary battery for example to the fastening screw of the starter
or to the engine body.
5.
When the engine starts, first remove the negative cable between the auxiliary battery and the engine
body. Then remove the positive cable.
5th Generation AWF Engines
8370 79929
41
2. Operation
GUID-7BD03211-4F48-49ED-9E11-7CEFE64EB5E5
2.6 Attention during operation
See instructions of the machine.
The fuel system is equipped with a pressure sensor that alarms before interference has developed.
Reasons can be for instance:
•
•
•
•
empty fuel tank
clogging fuel filters
suction pipe clogged or leaking air
unsuitable fuel (e.g. summer fuel in the winter).
NOTE: The automatic protection in the electronic control unit (ECU) on the engine limits the engine power
or forces to stop the engine as a consequence of certain defect codes. Observe the fault code display and
act accordingly.
• Check the coolant temperature. Normal running temperature is 75 - 95°C.
• Watch the ammeter reading/warning light.
NOTE: If the engine is overheated, cool it slowly down by idling for a few minutes. Never pour cold coolant
into hot engine! Never remove the 2-way thermostat to reduce the temperature. In that case a greater
quantity of the coolant is circulating via the by-pass pipe and the temperature is getting higher than before.
WARNING:
It is dangerous to open the cap of the pressurised hot radiator! If the coolant is hot, there
is an overpressure in the system. Open the radiator cap carefully.
NOTE: Avoid long periods of idling because then the temperature of combustion is reduced. This causes
incomplete combustion and carbon formation which may seize the nozzles and clog the valves and piston
rings.
42
5th Generation AWF Engines
8370 79929
2. Operation
GUID-22B5CA4D-C6EA-4287-84C0-913391D25902
2.7 Stopping the engine
See stopping instructions of the machine.
NOTE: Never stop a turbocharged engine immediately after heavy driving. Let it idle for a few minutes to
equalize the temperatures.
NOTE: If the electronic control system (ECU) self- diagnostics has shut the engine off, it can be re-started
by turning the current off and then starting again. If the cause of the stopping is not eliminated, the selfdiagnostics shuts the engine off again or does not allow it to start.
NOTE:
After engine shutdown, remaining DEF in the system has to be pushed back to DEF tank in order to avoid
any possible damage to DEF lines or DNOX2.2 components due to expansion effect of the freezing DEF
(DEF freezes at approximately -11°C) or due to evaporating of DEF.
SCR system management software of EEM4 takes care of the emptying process automatically, when
EEM4 detects that input of the ECU (ignition key) has been set off. During the emptying process,
continuous power supply must be provided for the EEM4 ECU.
Procedure
• Disconnect the current from the main switch if the engine is not at once again started.
• Do not cut off the current for alternator and electronic control unit as engine is running.
5th Generation AWF Engines
8370 79929
43
2. Operation
44
5th Generation AWF Engines
8370 79929
Table of contents
3. Maintenance
3.1 Periodical maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Maintenance charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.1
3.2.2
3.2.3
3.2.4
Maintenance chart
Maintenance chart
Maintenance chart
Maintenance chart
...................
...................
...................
...................
3.3 Maintenance to be made daily or at 10 hours intervals . . . . . . . . . . . . . . . . . . . .
3.3.1 Check the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Check coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Check for leakages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Maintenance to be made weekly or at 100 hours intervals . . . . . . . . . . . . . . . . .
3.4.1 Clean cooling system (from outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2 Examining the condition of the belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Maintenance to be made at 300 - 600 hours intervals . . . . . . . . . . . . . . . . . . . . . .
3.5.1 Change engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.2 Oil sump capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.3 Change oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.4 Update engine software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.5 How to recognize an engine with hydraulic lash adjusters . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6 Valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.1 Adjusting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.2 Checking valve clearances in 44 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.3 Checking valve clearances in 49 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.4 Checking valve clearances in 66 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.5 Checking valve clearances in 74 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.6 Checking valve clearances in 84 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.6.7 Checking valve clearances in 98 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Maintenance in 800-1200 hours intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.1 Change fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.2 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.3 Drain fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Maintenance to be made at 4000 hours intervals . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7.1 Check turbocharger play and check that the intercooler cell is clean . . . . . . . . . . . . . . . .
3.8 Maintenance to be made once a year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.1 SCR system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.2 Change SCR system main filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 Maintenance to be made every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9.1 Change coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Additional maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.1 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.2 Before the cold season . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.4 Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.5 Coolant quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.6 Fuel quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.6.1 Biodiesel blends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.7 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5th Generation AWF Engines
8370 79929
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67
69
69
70
71
72
45
Table of contents
46
5th Generation AWF Engines
8370 79929
3. Maintenance
GUID-F5332F2E-D0F7-41DE-92AA-68C8C5E5168F
3.1 Periodical maintenance
One of the most essential preconditions for secure operation of your engine is proper maintenance at
regular intervals. Maintenance costs are low compared to costs caused by negligence.
Maintenance work
DANGER:
Always stop the engine before maintenance.
Clean the engine and its surroundings before you start maintenance work.
NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers
when opening joints.
5th Generation AWF Engines
8370 79929
47
3. Maintenance
3.2 Maintenance charts
GUID-E3351143-F1C0-4262-921F-D4AA860C93AB
3.2.1 Maintenance chart
Maintenance chart for combine harvesters and sprayers with 84 and 98 engines.
Maintenance work
Service interval / running hours
10
Check engine oil level
x[1]
Check coolant level
x[1]
Check for oil, fuel or coolant leakages
x[1]
100
Clean cooling system (from outside)
x
Check the condition of the belt
x
300
900
x[2]
Change engine oil and oil filter
x[3]
Change fuel filters
Update engine software
x
Adjust valves[4, 5]
See Valve adjustment intervals table.
Turbocharger and intercooler inspection in an
authorized workshop
x
Change SCR supply module main filter
Once a year. [6]
Change coolant
Every two years.
Change the vibration damper (98 engines)
Every five years. [7]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
4000
or once a day.
or once a year (in the autumn).
or once a year (at the end of the season) or earlier if the engine control system notifies by specific service code.
The 98 engines have hydraulic lash adjusters from the engine serial number B52904. Do not adjust the valves.
In the spring 2016, AGCO Power started to install hydraulic lash adjusters gradually to different 84 AWF engines.
See for information, how to recognize an engine with hydraulic lash adjusters. Do not adjust the valves of an
engine, which has hydraulic lash adjusters!
or after 1200 running hours.
or after 8000 running hours.
Valve adjustment intervals[1, 2]
1st
2nd
3rd
4th
5th
300
1800
3600
5400
7200
[1]
[2]
The 98 engines have hydraulic lash adjusters from the engine serial number B52904. Do not adjust the valves.
In the spring 2016, AGCO Power started to install hydraulic lash adjusters gradually to different 84 AWF engines.
See for information, how to recognize an engine with hydraulic lash adjusters. Do not adjust the valves of an
engine, which has hydraulic lash adjusters!
GUID-14937AAB-E9BB-4C4F-9582-E64CEABB05CA
3.2.2 Maintenance chart
Maintenance chart for combine harvesters and sprayers with 33 - 74 engines.
48
5th Generation AWF Engines
8370 79929
3. Maintenance
Maintenance work
Service interval / running hours
10
Check engine oil level
x[1]
Check coolant level
x[1]
Check for oil, fuel or coolant leakages
x[1]
100
Clean cooling system (from outside)
x
Check the condition of the belt
x
400
800
x[2]
Change engine oil and oil filter
x[3]
Change fuel filters
Update engine software
x
Adjust valves
See Valve adjustment intervals table.
Turbocharger and intercooler inspection in an
authorized workshop
x
Change SCR supply module main filter
Once a year. [4]
Change coolant
Every two years.
[1]
[2]
[3]
[4]
4000
or once a day.
or once a year (in the autumn).
or once a year (at the end of the season) or earlier if the engine control system notifies by specific service code.
or after 1200 running hours.
Valve adjustment intervals
1st
2nd
3rd
4th
5th
400
2400
4800
7200
9600
GUID-17E4A930-284E-4A00-9464-8EB5C203E968
3.2.3 Maintenance chart
Maintenance chart for tractors and forest machines with 84 - 98 engines.
Maintenance work
Service interval / running hours
10
Check engine oil level
x[1]
Check coolant level
x[1]
Check for oil, fuel or coolant leakages
x[1]
100
Clean cooling system (from outside)
x
Check the condition of the belt
x
Change engine oil and oil filter
400
5th Generation AWF Engines
8370 79929
4000
x[2]
x[3]
Change fuel filters
Update engine software
800
x
49
3. Maintenance
Maintenance work
Service interval / running hours
10
Adjust valves[4, 5]
100
400
800
4000
See Valve adjustment intervals table.
Turbocharger and intercooler inspection in an
authorized workshop
x
Change SCR supply module main filter
Once a year. [6]
Change coolant
Every two years.
Change the vibration damper (98 engines)
Every five years. [7]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
or once a day.
or once a year (in the autumn).
or once a year (at the end of the season) or earlier if the engine control system notifies by specific service code.
The 98 engines have hydraulic lash adjusters from the engine serial number B52904. Do not adjust the valves.
In the spring 2016, AGCO Power started to install hydraulic lash adjusters gradually to different 84 AWF engines.
See for information, how to recognize an engine with hydraulic lash adjusters. Do not adjust the valves of an
engine, which has hydraulic lash adjusters!
or after 1200 running hours.
or after 8000 running hours.
Valve adjustment intervals[1, 2]
1st
2nd
3rd
4th
5th
400
2000
4000
6000
8000
[1]
[2]
The 98 engines have hydraulic lash adjusters from the engine serial number B52904. Do not adjust the valves.
In the spring 2016, AGCO Power started to install hydraulic lash adjusters gradually to different 84 AWF engines.
See for information, how to recognize an engine with hydraulic lash adjusters. Do not adjust the valves of an
engine, which has hydraulic lash adjusters!
GUID-00A49ED7-E002-41C7-B6B1-C748BFC4B79A
3.2.4 Maintenance chart
Maintenance chart for tractors and forest machines with 33 - 74 engines.
Maintenance work
Service interval / running hours
10
Check engine oil level
x[1]
Check coolant level
x[1]
Check for oil, fuel or coolant leakages
x[1]
100
Clean cooling system (from outside)
x
Check the condition of the belt
x
Change engine oil and oil filter
500
50
4000
x[2]
x[3]
Change fuel filters
Update engine software
1000
x
5th Generation AWF Engines
8370 79929
3. Maintenance
Maintenance work
Service interval / running hours
10
Adjust valves
100
500
1000
See Valve adjustment intervals table.
Turbocharger and intercooler inspection in an authorized
workshop
x
Change SCR supply module main filter
Once a year. [4]
Change coolant
Every two years.
[1]
[2]
[3]
[4]
4000
or once a day.
or once a year (in the autumn).
or once a year (at the end of the season) or earlier if the engine control system notifies by specific service code.
or after 1200 running hours.
Valve adjustment intervals
1st
2nd
3rd
4th
5th
500
2000
4000
6000
8000
5th Generation AWF Engines
8370 79929
51
3. Maintenance
3.3 Maintenance to be made daily or at 10 hours intervals
GUID-F4FBA864-3D6B-4B7B-B9C4-9553DDF97DF0
3.3.1 Check the engine oil level
Procedure
Stop the engine.
1.
2.
Wait for approximately 15 minutes.
3.
Do an oil level check.
The oil level must be between the MAX and
MIN lines on the oil dipstick.
4.
Add oil, if necessary.
Top up to the MAX line.
NOTE: Overfill causes excessive oil splash in
the crankcase, which results in increased oil
consumption and malfunction in crankcase
ventilation system (CCV). Major engine
damage can occur.
GUID-1595BCA1-ABA4-4E4C-87A1-AE5516435C98-high.eps
Fig. 1
GUID-86DC7196-65D2-412C-A8BA-FDCB9A8492F3
3.3.2 Check coolant level
The coolant level should be slightly above the radiator core.
The coolant level should be between the MAX and MIN lines if the system is provided with an expansion
tank.
Check the freezing point of the coolant before the cold season.
NOTE: Never use only water as coolant but a mixture of 40 - 60 % of water and antifreeze. See the
information for coolant quality requirements.
NOTE: The hot engine can be damaged if you pour cold coolant into it!
WARNING:
It is dangerous to open the cap of the pressurised hot radiator! If the coolant is hot, there
is an overpressure in the system. Open the radiator cap carefully.
GUID-DDCF3FAD-6F66-4A7C-815E-C30E98A05EDE
3.3.3 Check for leakages
Find any leakage points (fuel, oil, coolant) and
eliminate them as soon as possible.
The coolant pump is provided with a telltale hole
on the left side. This hole must not be blocked. If
coolant drops out of the hole, the coolant pump
must immediately be repaired.
There may be a slight leakage on a new pump
before it has been run in.
GUID-BE29A0E3-FA07-4D3B-89C4-CF5AF403CF24-high.eps
Fig. 2
52
5th Generation AWF Engines
8370 79929
3. Maintenance
3.4 Maintenance to be made weekly or at 100 hours intervals
GUID-904A5CAB-B87C-4043-B933-426C86EA19D5
3.4.1 Clean cooling system (from outside)
See also the instructions of the machine manufacturer.
Procedure
1.
Check and clean the outside of the radiator from time to time.
2.
Use compressed air or water spray to remove dirt and impurities.
• Avoid too high a pressure.
• The direction of the air or water spray must be against normal air flow.
GUID-1B07E6F7-F23D-4340-B4C6-C8E090A05F6C
3.4.2 Examining the condition of the belt
The engine is equipped with a spring loaded belt tensioner and the belt is of V-ribbed type. The tensioner
tightens the belt automatically during the operation.
See also the instructions of the machine manufacturer.
DANGER:
Make sure that the engine cannot be started during belt replacing. Disconnect the battery
before doing this job.
Procedure
Check the belt visually.
1.
Change a worn, oily or damaged belt.
2.
Replace a belt, if needed
Before removing the old belt check its
routing to make sure that the new belt is
fitted the same way.
Turn the tensioner against the direction of
tightening until the belt is loosened. Loosen
belts of possible accessories (e.g.
compressor).
• using a 3/8 in square drive inserted into
the square hole in the tensioner.
• pay attention to free rotation of tensioner
roller and also the right tightness of fixing
screw 48 Nm.
• fit the new belt and other loosened parts.
5th Generation AWF Engines
8370 79929
GUID-ADD4C06C-484C-48F1-8982-BB910B68F743-high.eps
Fig. 3
53
3. Maintenance
3.5 Maintenance to be made at 300 - 600 hours intervals
GUID-C7FA9363-FED4-4A80-889C-2EB2593D5680
3.5.1 Change engine oil
Oil change intervals depend on engine type and application:
Oil change intervals
Engine type
Tractor
Combine
harvester
Sprayer
Forest machine
98
400
300
300
400
84
400
300
300
400
74
500
400
400
500
66
500
400
400
500
49
500
400
400
500
44
500
400
400
500
33
500
400
400
500
See also instructions of the appliance.
Regarding oil grade, see Lubricating oil quality requirements.
Procedure
Run the engine until it is warm.
1.
2.
Stop the engine.
3.
Remove the draining plug and drain the oil
into a suitable container.
The engine may be equipped with an oil
draining pump (e.g. marine engines), in that
case use the pump to drain the oil.
4.
When the oil sump is empty, refit the plug
with a new washer.
5.
Fill new oil to the prescribed level (upper
mark line on dipstick) through the filler hole.
Note the capacity of the oil filter.
6.
Take old oil to a proper disposal point.
GUID-B6518140-1E52-4F7E-87D3-2EB7AFF6B9B3
3.5.2 Oil sump capacity
Number of cylinders
Oil sump part number
Minimum oil capacity
Maximum oil capacity
4 cylinders
8361 20641
9,5
11,5
8361 28794
8,0
10,0
8370 84513
13
17
8361 29147
8,0
10,0
54
5th Generation AWF Engines
8370 79929
3. Maintenance
Number of cylinders
Oil sump part number
Minimum oil capacity
Maximum oil capacity
6 cylinders
8363 47308
20,0
25,5
8363 36229
21,5
25,5
8370 74007
17
22
8370 84152
19
24
8370 84394
16
19
8368 73817
16
19
8368 74808
17
20
8368 84674
17
20
8368 84621
16,8
19,5
8368 73994
21
25
8368 74002
20
24
8368 73779
16,5
21,5
Number of cylinders
Oil sump part number
Minimum oil capacity
Maximum oil capacity
7 cylinders
8368 73028
27
33
8368 74866
29,5
35,5
GUID-EFF85558-12E7-4C73-B2A6-23CF6EC7831A
3.5.3 Change oil filter
NOTE: Engine Warranty is valid only when original AGCO Parts filter elements are used.
Procedure
Before removing the oil filter clean the
1.
surroundings of it.
2.
Use the loop tool to unscrew the old oil filter.
3.
Lubricate slightly the rubber gasket of the
new oil filter with clean motor oil and clean
the sealing faces.
4.
Rotate the new oil filter gently until the
gasket touches the opposite surface.
5.
Tighten the oil filter ¾ rounds (or one (1) full
round, if the height of the oil filter used is
260 mm). Use an appropriate tool for
tightening if necessary.
6.
Wipe off any oil run onto the chassis.
7.
Start the engine. Do not race.
8.
Ensure that no oil is leaking from the oil filter.
9.
Take the old oil filter to a proper disposal
point.
5th Generation AWF Engines
8370 79929
55
3. Maintenance
GUID-1E23D7F6-0FCA-4D43-9400-74EA1657CCF5
3.5.4 Update engine software
Engine software updates bring new features to the engine controller that improve the performance of the
engine, update diagnostic features and help to protect the engine and its emission components over
engine´s lifetime.
Procedure
1.
Use the service tool and examine, if new software is available for the machine.
2.
Update the engine software, if possible.
GUID-83FFFD66-C378-4F12-BBB7-6A1055F7CD94
3.5.5 How to recognize an engine with hydraulic lash adjusters
Hydraulic lash adjusters are used in some:
• 84 engines
• 98 engines
This instruction is valid only for 84 engines.
IMPORTANT: Do not adjust the valves of an
engine, which has hydraulic lash adjusters!
An engine with hydraulic lash adjusters has a
cylinder block, which has drillings for oil ways for
each hydraulic lash adjuster. If the cylinder block
has oil ways, there are screw plugs on the oil ways
in the cylinder block.
GUID-D19C4F02-BB60-4F75-A73E-9224770F6F33-low.svg
The screw plugs are in the same locations, where
the hydraulic lash adjusters or valve tappets are.
For example, one location is above the engine
plate.
(1)
Fig. 4
Screw plug
NOTE: The same cylinder block is used in some
engines, which do not have the hydraulic lash
adjusters.
Procedure
1.
Examine the cylinder block for screw plugs on oil ways.
Result
If the cylinder block has no screw plugs, the engine does not have hydraulic lash adjusters.
2.
If the cylinder block has screw plugs, examine the screw head of the screw plug.
Result
If the screw head of the screw plug has two levels, the engine does not have hydraulic lash
adjusters.
GUID-6175EAB7-8664-4EDD-ADDC-86B358C52959-low.svg
Fig. 5 The screw head has two levels.
56
5th Generation AWF Engines
8370 79929
3. Maintenance
If the screw head of the screw plug is flat, the engine has hydraulic lash adjusters.
GUID-B2487765-E008-4158-878E-4F4B2A4F25F7-low.svg
Fig. 6 The screw head is flat.
GUID-2CFCF487-EC0C-463F-BC68-EFE7822800DD
3.5.6 Valve clearances
NOTE: See the adjusting intervals of the valve clearances in the maintenance chart.
The nominal clearance of the inlet valves and the exhaust valves is 0,35 mm. The valve clearances can be
examined if the engine is cold or hot. The valve clearances of a cylinder can be adjusted when the piston is
at its top dead centre of the compression stroke. The valves for different cylinders are adjusted in the
same sequence as the injection sequence.
GUID-B35DCB07-2620-49D6-BC65-010900139C3F
3.5.6.1 Adjusting valves
The adjustment has to be made from the space between the rocker and the connecting cap as shown in
the picture.
Procedure
1.
Loosen the lock nut on the adjusting screw.
2.
Check the clearance with a feeler gauge and adjust to 0,35 mm by turning the adjusting screw.
3.
Tighten the lock nut and check again that the clearance is correct.
GUID-8D494411-26B1-418A-95B5-633BE85A99E5
3.5.6.2 Checking valve clearances in 44 engines
Procedure
1.
Rotate the crankshaft in the running direction until the valves in the 4th cylinder are rocking (exhaust
closes, inlet opens).
2.
Check the valve clearance of the 1st cylinder.
3.
Rotate the crankshaft by 1/2 of a turn in the running direction so that valves in the 3rd cylinder are
rocking.
4.
Check valves in the 2nd cylinder.
5.
Continue according to the order of injection.
Injection order
1-2-4-3
Valves rock in cyl. no.
4-3-1-2
GUID-400B1E00-F456-48A0-B81E-D62AB48F84F2
3.5.6.3 Checking valve clearances in 49 engines
Procedure
1.
Rotate the crankshaft in the running direction until the valves in the 4th cylinder are rocking (exhaust
closes, inlet opens).
2.
Check the valve clearance of the 1st cylinder.
3.
Rotate the crankshaft by 1/2 of a turn in the running direction so that valves in the 3rd cylinder are
rocking.
5th Generation AWF Engines
8370 79929
57
3. Maintenance
4.
Check valves in the 2nd cylinder.
5.
Continue according to the order of injection.
Injection order
1-2-4-3
Valves rock in cyl. no.
4-3-1-2
GUID-F69E43D8-8FBF-4158-BA0F-6A8D1B538E7D
3.5.6.4 Checking valve clearances in 66 engines
Procedure
1.
Rotate the crankshaft in the running direction until the valves in the 6th cylinder are rocking (exhaust
closes, inlet opens).
2.
Check the valve clearance of the 1st cylinder.
3.
Rotate the crankshaft by 1/3 of a turn in the running direction so that valves in the 2nd cylinder are
rocking.
4.
Check valves in the 5th cylinder.
5.
Continue according to the order of injection.
Injection order
1-5-3-6-2-4
Valves rock in cyl. no.
6-2-4-1-5-3
GUID-55DA341D-C55B-4614-8881-57D275DC9991
3.5.6.5 Checking valve clearances in 74 engines
Procedure
1.
Rotate the crankshaft in the running direction until the valves in the 6th cylinder are rocking (exhaust
closes, inlet opens).
2.
Check the valve clearance of the 1st cylinder.
3.
Rotate the crankshaft by 1/3 of a turn in the running direction so that valves in the 2nd cylinder are
rocking.
4.
Check valves in the 5th cylinder.
5.
Continue according to the order of injection.
Injection order
1-5-3-6-2-4
Valves rock in cyl. no.
6-2-4-1-5-3
GUID-CF93CAC3-4E97-496C-AF43-C77051E09957
3.5.6.6 Checking valve clearances in 84 engines
Procedure
1.
Rotate the crankshaft in the running direction until the valves in the 6th cylinder are rocking (exhaust
closes, inlet opens).
2.
Check the valve clearance of the 1st cylinder.
3.
Rotate the crankshaft by 1/3 of a turn in the running direction so that valves in the 2nd cylinder are
rocking.
4.
Check valves in the 5th cylinder.
5.
Continue according to the order of injection.
58
Injection order
1-5-3-6-2-4
Valves rock in cyl. no.
6-2-4-1-5-3
5th Generation AWF Engines
8370 79929
3. Maintenance
GUID-01C1DC66-A74B-4B76-8EB1-CBF7C3B5E57A
3.5.6.7 Checking valve clearances in 98 engine
Procedure
1.
Rotate the crankshaft in the running direction until the valves in the 6th cylinder are rocking (exhaust
closes, inlet opens).
2.
Check the valve clearance of the 1st cylinder.
3.
Rotate the crankshaft in the running direction so that valves in the 7th cylinder are rocking.
4.
Check valves in the 2nd cylinder.
5.
Continue according to the order of injection.
Injection order
1-2-4-6-7-5-3
Valves rock in cyl. no.
6-7-5-3-1-2-4
5th Generation AWF Engines
8370 79929
59
3. Maintenance
3.6 Maintenance in 800-1200 hours intervals
GUID-D15E8AA3-7AF9-46A8-B256-177610E6E188
3.6.1 Change fuel filters
Absolute cleanliness is required when servicing fuel system.
NOTE:
Pre-filter and main-filter elements are delivered as a filter set. Single filter elements are not available as
spare parts. Set includes pre-filter water detector gasket.
NOTE: Take the old filter elements to a proper disposal point.
NOTE: Engine Warranty is valid only when original AGCO Parts filter elements are used.
Procedure
Clean the fuel filters and surrounding area.
1.
2.
Disconnect the pre-filter water detector
connector.
3.
Use the fuel filter wrench 8370 79717 to
open the pre-filter element and remove the
pre-filter element from its mounting bracket.
4.
Collect the fuel into a suitable container.
5.
Detach the water detector from the pre-filter
bottom end.
6.
Remove the main filter in a similar way.
7.
Attach the water detector to the new prefilter bottom end.
8.
Lubricate the filter element o-ring seal with
clean fuel.
Fill the outer shell of the filter element with
clean fuel.
9.
10.
Use the fuel filter wrench 8370 79717 and
turn the filter element to its mounting
bracket until the plastic flange contacts the
bracket.
11.
Connect the water detector connector.
12.
Install the main filter in a similar way.
13.
Bleed the fuel system.
GUID-55BCF26C-95F3-4A3E-9663-367B6EDAC9CD-low.svg
Fig. 7
See information for bleeding the fuel system.
14.
Start the engine and make sure that there
are no leaks.
GUID-07107D8C-2135-423C-AE1E-ECAD7E69BA92-high.eps
Fig. 8
GUID-B48DC3D5-DAA5-4C22-BB5A-A89756AA98B7
3.6.2 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. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
60
5th Generation AWF Engines
8370 79929
3. Maintenance
Procedure
Open the bleeding plug on the pre-filter
1.
bracket.
2.
Put a transparent hose in the plug hole and
lead it into a suitable container.
3.
Pump fuel with the hand pump on top of the
pre-filter.
4.
Pump with the hand pump until there are no
air bubbles in the fuel stream.
5.
Remove the hose and turn in the bleeding
plug.
6.
Clean the engine of eventual overspill fuel.
GUID-C0ECB672-D82E-43F4-950E-A0B7FDF50001-high.eps
Fig. 9
7.
Start the engine. The fuel system removes automatically the air left in the system.
NOTE: Do not use the hand pump when the engine is running. Do not use any tools or excessive
force on the pre-filter hand pump.
NOTE: The fuel system is equipped with a pressure sensor that alarms before interference has
developed. Reasons can be for instance:
•
•
•
•
Empty fuel tank.
Clogged fuel filters.
Suction piping clogged or leaking air.
Unsuitable fuel (e.g. summer fuel in the winter).
NOTE: Use of spirits as antifreeze is not useful or recommended at all. It makes the fuel solidify and
weakens the lubricating qualities of the fuel and increases the possibility of corrosion.
GUID-09EE485F-A475-495F-8031-7B343828068A
3.6.3 Drain fuel tank
The fuel tank should be cleaned before the winter. Thus you avoid troubles caused by the water in the fuel
system. The best way to prevent condensation is to always keep the fuel tank as full as possible.
See also the instructions of the machine manufacturer.
Procedure
1.
Empty the fuel tank and rinse it with pure fuel.
2.
Fill the fuel tank with fuel for winter conditions.
See information for fuel quality requirements.
5th Generation AWF Engines
8370 79929
61
3. Maintenance
3.7 Maintenance to be made at 4000 hours intervals
GUID-85E73C9E-514F-444F-BC22-B09705AA08F2
3.7.1 Check turbocharger play and check that the intercooler cell is clean
The turbocharger and the intercooler cell service
must be entrusted to an expert technician at
AGCO Power Service.
It is essential to carry out regular engine services
to keep the turbocharger in good condition. Special
attention must be paid to the cleanliness of the air
filter cartridge and to the engine oil and oil filter
change at recommended intervals. Check regularly
that the turbocharger is properly fitted to the
exhaust manifold as well as the tightness of the
inlet and exhaust manifold joints. Correct
adjustment of the injection equipment is essential
for the operation of the turbocharger.
When a new turbocharger is installed, pour about
0,1 ltr of pure engine oil into the bearing housing
before attaching the pressure oil pipe. Ensure that
no impurities are entering the turbocharger with
the oil.
GUID-6B03777A-6985-40C2-AC63-DCD2CD921CCF-low.jpg
Fig. 10
62
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3. Maintenance
3.8 Maintenance to be made once a year
GUID-0738A23D-77EE-4FB0-94BE-668A6183EB4A
3.8.1 SCR system maintenance
AGCO POWER SCR system is durable and almost maintenance free. Only main filter change for supply
module is required in normal use. AGCO POWER SCR is equipped with on-board diagnostic, which will
warn the operator or limit the usage of the machine if any problems (e.g. leakages or blocking of lines)
occur in the system.
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.
CAUTION:
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used as a reducing
agent. Diluting of DEF or mixing it with other substances is not allowed, it may damage
the catalyst!
CAUTION:
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used as a reducing
agent. If urea quality sensor detects a problem related to urea quality, it will alert the
engine control system via CAN message thus causing the engine to run under degraded
mode.
CAUTION:
Even small amounts of diesel fuel in DEF tank may damage the gaskets of the SCR
system!
CAUTION:
The storage of DEF must be done under 30°C, avoiding direct sunlight.
GUID-6FC704BC-951D-4137-AE15-48E2E7998003
3.8.2 Change SCR system main filter
The main filter is located under the filter cover in
the supply module of DNOX2.2-system. No special
tools are needed for filter change.
NOTE: It must be checked if there are cracks
around the area of the filter cover. No cracks in the
material are allowed. If there are cracks in the
housing the entire supply module must be
replaced! If there are cracks in the filter cover the
filter cover must be replaced.
Take the old equalizing element and filter element
to a proper disposal point.
GUID-7E5881D5-8D42-42E5-81D2-BDCD85FC756C-low.jpg
Fig. 11
CAUTION:
All the sealing surfaces on the filter
cover, equalizing element, filter
element and supply module housing
must be absolutely clean and
undamaged!
5th Generation AWF Engines
8370 79929
63
3. Maintenance
CAUTION:
Do not install used or wet filter or
equalizing element. Danger of engine
damage and poor filtration.
CAUTION:
Do not use mineral or silicone oils or
greases when assembling the filter
seals! All seals have teflon coating.
GUID-3F4B1B80-BA08-47A5-B5E8-9825DC7FEF33-low.jpg
Fig. 12
Procedure
1.
Turn the filter cover anti-clockwise with a 27mm spanner and remove the cover.
2.
Pull out the equalizing element.
3.
Pull out the filter element with small pliers.
4.
Insert new filter element and equalizing element.
5.
Install the filter cover back; tighten to 22,5 +/- 2,5 Nm with a 27 mm spanner.
64
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3. Maintenance
3.9 Maintenance to be made every two years
GUID-0E452FE8-8E70-401A-8851-CE80DFF8BDB2
3.9.1 Change coolant
(1)
(2)
(3)
(4)
Drain plug on radiator
Drain plug on cylinder block
Drain plug on oil cooler
Bleed plug
Change the coolant every two years. This ensures
that the anti-corrosive is always active. See
information for coolant quality requirements.
GUID-06D0CE8F-7E47-4747-87DD-F4712A58C83F-low.jpg
Fig. 13
Procedure
1.
Drain the cooling system.
a) Remove the filler cap.
b) Remove the draining plugs on the radiator and on the left side of the cylinder block.
c) Remove the draining plugs on the oil cooler.
d) The engine assembly may also have other draining plugs (e.g. on the engine heater piping).
Remove also these plugs.
e) Drain the coolant.
Make sure all coolant is drained out and no impurities are blocking the draining hole.
2.
Examine the tightness and condition of the rubber hoses of the cooling system.
3.
Replace damaged rubber hoses.
4.
Fill cooling system.
a) Fill the cooling system with a mixture of
antifreeze and coolant until the coolant
level comes above the radiator core.
b) Bleed the cooling system by removing
the air venting plug/temperature sensor
on the thermostat housing.
c) Pour coolant until the coolant level
reaches the plug.
d) Screw in the plug and fill rest of the
system.
NOTE: Never use only water as coolant but a
mixture of 40 - 60 % of water and antifreeze.
See the information for coolant quality
requirements.
5th Generation AWF Engines
8370 79929
GUID-EE6ADAB9-3ECA-4D47-9484-6E50DF166BAC-high.eps
Fig. 14
65
3. Maintenance
3.10 Additional maintenance instructions
GUID-B48DC3D5-DAA5-4C22-BB5A-A89756AA98B7
3.10.1 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. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
Procedure
Open the bleeding plug on the pre-filter
1.
bracket.
2.
Put a transparent hose in the plug hole and
lead it into a suitable container.
3.
Pump fuel with the hand pump on top of the
pre-filter.
4.
Pump with the hand pump until there are no
air bubbles in the fuel stream.
5.
Remove the hose and turn in the bleeding
plug.
6.
Clean the engine of eventual overspill fuel.
GUID-C0ECB672-D82E-43F4-950E-A0B7FDF50001-high.eps
Fig. 15
7.
Start the engine. The fuel system removes automatically the air left in the system.
NOTE: Do not use the hand pump when the engine is running. Do not use any tools or excessive
force on the pre-filter hand pump.
NOTE: The fuel system is equipped with a pressure sensor that alarms before interference has
developed. Reasons can be for instance:
•
•
•
•
Empty fuel tank.
Clogged fuel filters.
Suction piping clogged or leaking air.
Unsuitable fuel (e.g. summer fuel in the winter).
NOTE: Use of spirits as antifreeze is not useful or recommended at all. It makes the fuel solidify and
weakens the lubricating qualities of the fuel and increases the possibility of corrosion.
GUID-35C6AC3F-5A1A-4A53-A572-BCA4722492BE
3.10.2 Before the cold season
Procedure
1.
Drain the fuel tank of water.
2.
Replace the fuel filter and pre-filter.
3.
Ensure that the fuel in the tank is of winter quality.
4.
Change the engine oil (winter quality).
5.
Check the battery condition.
6.
Check the function of the intake air heater.
7.
Check the function of the coolant pre-heater.
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3. Maintenance
GUID-14288225-674A-4E72-AD44-BDCA8FA55D33
3.10.3 Tightening torques
Object
Nm
Cylinder head bolts
80 Nm + 90° + 90°
Main bearing screws
200
Connecting rod screws
• M12
• 40 Nm > 80 Nm + 90°
• M14
• 40 Nm > 80 Nm + 90° + 90°
Crankshaft nut (33/44/49)
600
Crankshaft nut (66/74/84/98)
1000
Crankshaft pulley screws
30
Crankshaft pulley screws (74/84/98)
80
Flywheel screws
150
Flywheel screws (84/98)
200
Flywheel housing screws:
• M12
• 150
• M10
• 80
Idler gear screws :
• M14
• 180
• M8
• 32
Small idler gear screws (shaft, 2 pcs): M8
45
Small idler gear screws (thrust ring): M8
32
Camshaft gear nut
200
Rocker arm shaft bracket screw and nuts
45
Valve cover and frame screws
25
Piston cooling valve
30
Oil pump retaining screws
60
Oil sump drain plug M18
80
Oil cooler connecting piece
60
Coolant pump pulley screw
• M10
• 50
• M12
• 80
Coolant pump pulley nut M16
120
Belt tightener screw
48
Exhaust manifold screws
50
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67
3. Maintenance
Object
Nm
Injector (CRIN3) retaining screw
40
Injector (CRI2_16) retaining screw
28
Injector wire nuts (M4)
1,5
High pressure pump gear nut
80
Pre-filter water detector
6
Compressor gear nut (1 and 2 cylinder)
160 (LH thread)
Self carrying oil sump screws and engine bracket screws
Thread
Nm
M8
35
M10
80
M12
140
M14
200
M16
300
M20
700
M22
700
General torque values
Always use the torque values listed in the
following table when specific torque values are not
available.
Use a washer with the aluminum parts.
68
Thread
Strength class
8.8
10.9
M8
25 Nm
35 Nm
M10
50 Nm
75 Nm
5th Generation AWF Engines
8370 79929
3. Maintenance
GUID-3C83A33F-B7E5-40BD-A03B-CE6E035A1BB8
3.10.4 Lubricating oil quality requirements
Use lubricating oils fulfilling following quality
grades.
Engine type
API-grade
CJ-4
AWF (Tier 4
final, with
aftertreatment)
ACEA-grade
E9
Select viscosity grade from Oil viscosity -table
corresponding to outside temperature.
See oil capacities at Oil sump capacities.
GUID-D7ACC699-5F57-4C42-9027-1BD6FE25BEFF-low.jpg
Fig. 16 Oil viscosity
DANGER:
Lubricating oil is hazardous to health. Avoid prolonged contact with the skin. The oil mist
is dangerous to inhale.
GUID-5C9A453D-3B9B-4DD7-A6D0-BE179CA6E967
3.10.5 Coolant quality requirements
AGCO Power Inc. recommends to use coolants that follow in all AGCO POWER engines:
• Arteco, Havoline XLC
• BASF, Glysantin G30
In addition, coolants under other brand names, which can be proved to use exactly the same inhibitor
package as Arteco Havoline XLC or BASF Glysantin G30, are recommended to be used.
If Arteco Havoline XLC, BASF Glysantin G30 or coolant which uses the same inhibitor package is used, the
coolant change interval can be extended from two years up to five years. If any other coolant is used, the
coolant change interval is two years.
5th Generation AWF Engines
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69
3. Maintenance
Requirements
The coolant used must meet the demands of
standard ASTM D 3306 or BS 6580:1992.
• The cooling mixture must consist 40 - 60 % of
ethylene/propylene-glycol based antifreeze and
water. The best proportion is 50 % of
antifreeze liquid and 50 % of water.
• The water used must be mechanically clean
and not too acid (e.g. swamp water) or too hard
(calciferous well water).
• Check periodically the proportion of antifreeze
(the frost resistance) in the coolant.
• Do not mix ethylene- and propylene-glycol
based antifreeze.
• Change the coolant every two years.
GUID-EE6ADAB9-3ECA-4D47-9484-6E50DF166BAC-high.eps
Fig. 17
NOTE: Never use only water as coolant but a
mixture of 40 - 60 % of water and antifreeze. See
the information for coolant quality requirements.
DANGER:
Antifreeze is hazardous to health. Avoid contact with the eyes and skin.
GUID-61202AC9-CDDD-41EF-A705-ED13236ADD21
3.10.6 Fuel quality requirements
Use of fuel, which does not fulfil the requirements that follow, can cause multiple malfunctions in the fuel
injection system and aftertreatment system. Malfunctions can cause serious issues in the other engine
components and shorten the engine lifetime. Also the engine will not meet the emission requirements, if
the used fuel is not permitted for the engine.
AGCO Power (and AGCO Corporation) is not responsible of any failures or issues caused by inappropriate
quality or storage of fuel.
CAUTION:
Risk of serious failure in the fuel system! Diesel exhaust fluid (DEF) in the diesel fuel, even
in small amounts, will cause serious failure in the fuel system. If there is a doubt that fuel
has been contaminated with DEF, engine must not be started before emptying and
cleaning the fuel tank.
Fuel standards
Fuel must meet sulfur requirements, biodiesel requirements and standards that follow:
European standard
EN 590
2009 or newer
North American standard
ASTM D 975 or ASTM D7467
(B20)
10b or newer
Japanese standard
JIS K2204
2007 or newer
Chinese standard
GB 252 or GB 19147
>07/2013
Ultra low sulfur (≤ 15 mg/kg) diesel fuels that fulfill requirements of EN 590 (:2009 or newer), ASTM D 975
(-10b or newer), or GB 19147 Stage V can be used in all AGCO POWER engines.
CAUTION:
Supplementary admixtures or additives are not allowed.
Fuels or mixtures which include e.g. ethanol, gasoline or kerosene are not permitted to be used since they
can shorten the expected lifetime and cause severe system failure.
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3. Maintenance
Permitted sulfur contents
Permitted sulfur content depends on:
• emission level
• fuel injection components and materials
• aftertreatment components and materials.
For engines with SCR system and engines with cooled external EGR system (cEGR), fuels with higher
sulfur content are not permitted because engines do not fulfill particulate emission limits with high sulfur
fuel. Sulfur is also a catalyst poison, which can lead to catalyst deactivation in long term use. Deactivation
will cause malfunction of the aftertreatment system.
IMPORTANT: Use of high sulfur fuel in SCR engines and cEGR engines will lead to severe damage to
emission aftertreatment components and cause the machine to derate. Warranty of the engine and
exhaust aftertreatment system will be voided if high sulfur content fuels are used.
Permitted sulfur contents
Emission level
Fuel injection system
Aftertreatment system
(DOC, SCR, EGR)
Maximum permitted
sulfur content
Tier 4 Final, Stage 4
Common rail
Yes
15 mg/kg
Tier 4 Interim, Stage 3B
Common rail
Yes
15 mg/kg
Tier 3, Stage 3A
Common rail
Yes
15 mg/kg or 500 mg/
kg[1]
Tier 2, Stage 2
Common rail
Yes
15 mg/kg or 500 mg/
kg[1]
Common rail
No
2000 mg/kg
Mechanical
No
2000 mg/kg
Common rail
No
2000 mg/kg
Tier 0, Stage 0
Mechanical
[1]
If the engine does not have SCR system or cooled external EGR system, maximum permitted sulfur content is
500 mg/kg.
Cetane number
Cetane number must be minimum 43. Cetane number above 47 is preferred, especially for temperatures
below -20°C (-4°F) and elevations above 1500m (5000 ft) from the sea level.
GUID-AD5AADED-73BD-40DC-8D56-B22AE0A590D7
3.10.6.1 Biodiesel blends
1st generation biodiesel blends
Use of 1st generation biodiesel, which has less than 10% fatty acid methyl esters (FAME) / fatty acid
mono-alkyl esters (FAAE), does not require changes in engine or its maintenance.
Allowed fuels
Maximum allowed 1st
generation biodiesel content
Standard for biodiesel blend
EN 590 - Europe
0 - 10% fatty acid methyl esters
(FAME) / fatty acid mono-alkyl
esters (FAAE)
EN 14214
ASTM D 975 - North America
ASTM D 6751
JIS K2204 - Japan
JIS K2390
GB 19147 St5 - China
-
TS 15940 EU BTL/HVO
EN 14214
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71
3. Maintenance
Use of higher (10-20%) biodiesel proportions requires changes in the engine and its maintenance as
follows:
• You must change oil, oil filter and fuel filter elements twice as often than with less than 10% biodiesel
content.
• Engine must have an additional fuel pre-filter or water separator in the fuel line between the fuel tank
and the engine. The water separator requires frequent checks.
• The additional fuel pre-filter (inclusive water separator) must be specified and approved by AGCO
Power.
Use of higher biodiesel proportions are not allowed!
Consequences of use of fuels with 1st generation biodiesel blends
If you use biodiesel blends from 10% to 20%, you must consider the risks:
•
•
•
•
•
•
•
•
Possible power and fuel economy reduction even up to 6%.
Reduced fuel flow in cold environment.
Possible fuel filters restriction and plugging.
Possible fuel leakage through damaged seals and hoses.
Possible coking of fuel injector nozzles.
Possible engine oil dilution.
Possible high acid levels within fuel system.
Possible compatibility issues with other materials (including copper, lead, zinc, tin, brass and bronze)
used in fuel handling process.
• Reduction of service life on engine and exhaust system systems (SCR and cEGR).
• Increase of engine emissions that can lead engine to de-rate on SCR engines.
All the above mentioned risks are bigger with higher than 20% biodiesel blends. In addition higher
biodiesel blends cause other problems:
•
•
•
•
Blockage of injector nozzles, resulting loss of power and engine malfunction.
Crankcase oil soot formation, which results in shorter oil and oil filter lifetime.
Corrosion of fuel injection equipments.
Seizure of engine or internal components of the injection system.
GUID-3708FF2B-0DDE-4969-B3D6-EA128402AC74
3.10.7 Air filter
See the instructions of the machine manufacturer for air filter change and maintenance.
72
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Table of contents
4. Troubleshooting
4.1 Engine control system fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2 Troubleshooting of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5th Generation AWF Engines
8370 79929
73
Table of contents
74
5th Generation AWF Engines
8370 79929
4. Troubleshooting
GUID-D240FA20-93F4-446E-9CC8-F585EB662E48
4.1 Engine control system fault codes
NOTE: See also the instructions of the machine manufacturer.
When the control system uses the CAN bus, all the filed or active fault reports in the system can be read/
write out from the display in cabin.
The electronic control unit (ECU) self-diagnostics monitors different functions in the engine giving a fault
report in case of possible disturbance. Additionally in certain cases, it limits the engine power, performing a
so called delayed stopping or a so called forced stopping. The code in the display tells the cause. Some
functions are optional.
If a fault code appears, contact an authorized service.
NOTE: If the engine stops or the power decreases without any code in the display, the cause might be a
fault outside the supervision of the control system, momentary overload or a mechanical damage, see
information for troubleshooting of the engine.
If the self-diagnostics has stopped the engine, it can be started again by disconnecting the current and
starting again. If the cause of the stopping is not eliminated, the self-diagnostics stops the engine again or
does not allow it to start.
NOTE: The ECU engine control system can only be ruled by electronic service tool. The ECU system
service must be entrusted to an expert at AGCO Power service.
5th Generation AWF Engines
8370 79929
75
4. Troubleshooting
GUID-13C7689D-B0AD-47D6-A816-CB2E0F9DE40A
4.2 Troubleshooting of the engine
NOTE: See also engine control system fault codes.
Engine can not be cranked
Cause(s)
Loose or broken wire.
Battery discharged. This may be due to a slackened or broken alternator belt.
Starter defective.
Ignition switch defective.
Application control system doesn't allow engine to crank.
Engine fails to start
Cause(s)
Fuel tank empty.
Fuel not fluid enough in cold weather (summer quality).
Air in fuel system.
Leak in fuel inlet or delivery pipe.
Clogged fuel filter or pipe.
Low compression.[1]
a
b
c
d
leaky valves
piston rings sticking
cylinder head gasket damaged
broken valve spring
Common rail system defective. [1]
a
b
c
d
injectors defective
high-pressure pump defective
pressure control valve (PCV) defective
engine control unit (ECU) defective
Wiring harness defective.
Clogged intake air system.
[1]
Consult an expert technician.
Engine starts but stops after a short while
Cause(s)
Air in fuel system.
Fuel strainer in fuel tank air pipe clogged.
Clogged fuel filters or pipe.
76
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4. Troubleshooting
Engine starts but stops after a short while
Cause(s)
Clogged water separator.
EEM4 self-diagnostic has discovered fault in system.[1]
ECU power supply failure.
Common rail system defective (see Engine fails to start, Common rail system defective). [1]
[1]
Consult an expert technician.
Engine does not run smoothly
Cause(s)
Air in fuel system.
Clogged fuel filters or pipe.
Leak in fuel inlet or delivery pipe.
Common rail system defective (see Engine fails to start, Common rail system defective). [1]
Low compression (see Engine fails to start, Low compression).[1]
EEM4 control unit or speed sensors defective.[1]
[1]
Consult an expert technician.
Engine does not develop full power
Cause(s)
Air filter clogged.
Turbocharger defective. [1]
Air in fuel system.
Clogged fuel filter, pre-filter, water separator or fuel pipe.
Leak in fuel inlet or delivery pipe.
Low compression (see Engine fails to start, Low compression).[1]
Common rail system defective (see Engine fails to start, Common rail system defective). [1]
EEM4 has detected fault in engine operation. [1]
Engine running too cold.
Leakage in turbocharging system.
[1]
Consult an expert technician.
5th Generation AWF Engines
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77
4. Troubleshooting
Abnormal engine running sound
Cause(s)
Incorrect fuel.
Common rail system defective (see Engine fails to start, Common rail system defective). [1]
Incorrect valve clearance.
Valve mechanism defect.
Crank mechanism defect.
Timing mechanism defect.
Power train defect.
[1]
Consult an expert technician.
Engine smoking abnormally
Cause(s)
Engine running too cold.
Engine has been idling for too long.
Air filter clogged.
Incorrect fuel.
Engine oil level too high.
Common rail system defective (see Engine fails to start, Common rail system defective). [1]
Air in fuel system.
Closed crankcase ventilation (CCV) defective.
Internal coolant leakage.
a
b
c
EGR cooler
Interstage charge air cooler (ICAC)
cylinder head / gasket
Low compression (see Engine fails to start, Low compression).[1]
Glogged intake air system
Turbocharger defective.[1]
Leakage in turbocharging system.
[1]
Consult an expert technician.
Engine overheats
Cause(s)
Slack or broken fan belt.
Cooling system not completely filled. System clogged.
Thermostat defective or removed (double-acting thermostat).
78
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4. Troubleshooting
Engine overheats
Cause(s)
Thermostat upside down.
Radiator filler cap not pressure tight.
Overloading.
Radiator clogged.
Water pump defective.
Engine tends to race or fails to maintain its standard speed
Cause(s)
Closed crankcase ventilation (CCV) defective.
Engine oil level too high.
Maximum tilting angle exceeded.
Oil pressure too low
Cause(s)
Engine has run short of oil.
Impurities in oil pressure regulating valve.
Incorrect SAE grade of oil.
Oil too hot.
Excessive bearing clearance.[1]
Idling speed too low.
Oil pressure sensor defective.
Oil pressure gauge shows incorrect reading.
Oil filter clogged.
Oil diluted by fuel.
Clogged oil cooler.
[1]
Consult an expert technician.
5th Generation AWF Engines
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79
4. Troubleshooting
80
5th Generation AWF Engines
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Index
Index
A
air control system ..........................................................
egr ..................................................................... 24
air filter ..................................................................... 72
I
interstage charge air cooling .........................................
icac .................................................................... 23
B
biodiesel ................................................................... 71
biofuel ....................................................................... 71
C
cold ...........................................................................
cold start ...................................................................
coolant ......................................................................
coolant quality ..........................................................
cooling of inlet air .....................................................
cooling system .........................................................
hydraulic lash adjuster ...................................................
HLA ................................................................... 56
hydraulic lash adjustment ......................................... 56
66
40
65
69
23
31
L
lubrication oil .................................................................
requirements ..................................................... 69
lubrication system .................................................... 29
M
diesel exhaust fluid ........................................................
def ..................................................................... 33
dosing module .......................................................... 34
maintenance ..................................................................
10 hours ............................................................ 52
4000 hours ........................................................ 62
daily ................................................................... 52
engine oil ........................................................... 54
intercooler ......................................................... 62
turbocharger ...................................................... 62
maintenance chart .............................................. 48–50
E
O
ECU ...............................................................................
type plate .......................................................... 10
electrical system ...................................................... 32
engine ............................................................................
starting .............................................................. 39
troubleshooting ................................................. 76
engine control system ...................................................
fault codes ......................................................... 75
engine control unit .........................................................
ecu .................................................................... 27
engine heater ........................................................... 31
engine oil level .......................................................... 52
engine overview ....................................................... 14
engine serial number .....................................................
location ................................................................ 9
engine software ............................................................
update ............................................................... 56
engine type ................................................................. 8
oil cooler ................................................................... 30
oil filter ................................................................ 30, 55
oil pressure regulating valve ..................................... 30
oil sump .........................................................................
capacity ............................................................. 54
operation .................................................................. 42
D
F
fan belt .....................................................................
fuel filter ...................................................................
fuel quality requirements ..........................................
fuel system ...............................................................
53
60
70
25
H
HLA ...............................................................................
hydraulic lash adjuster ....................................... 56
5th Generation AWF Engines
8370 79929
P
pre-start .................................................................... 38
S
scr ..................................................................................
maintenance ...................................................... 63
starting ..........................................................................
auxiliary battery ................................................. 41
starting the engine ................................................... 39
stopping the engine .................................................. 43
supply module .......................................................... 34
T
technical data ................................................................
cooling system .................................................. 13
dimensions ........................................................ 12
fuel system ....................................................... 12
lubrication system ............................................. 13
throttle valve ............................................................. 23
torques ..................................................................... 67
81
Index
troubleshooting of the engine .................................. 76
turbocharging ..................................................... 22, 23
V
valve clearances ................................................. 57–59
W
warming up .............................................................. 40
weekly maintenance .....................................................
clean cooling system ......................................... 53
82
5th Generation AWF Engines
8370 79929
© AGCO Corporation, 2016. All rights reserved.
8370 79929 (English)
April 2016
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