download repair manual

1. SERVICE MANUAL
FASTRAC (AGRICULTURAL TRACTOR)
4160, 4190, 4220
EN - 9813/3600 - ISSUE 3 - 07/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
28 - Suspension System
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

2. 15 - Engine
51 - Timing Gear
00 - General
15 - 143 9813/3600-3 15 - 143
00 - General
Introduction .................................................. 15-143
Technical Data ............................................. 15-145
Component Identification ............................. 15-145
Operation ..................................................... 15-146
Remove and Install ..................................... 15-147
Introduction
The timing gears are located inside a case at the
flywheel end of the engine.
The engine must be timed so that the camshaft
operates the valves at the correct times relative to
the crankshaft position.
The timing gear drives the camshaft, high pressure
pump and the oil pump. The timing gear train consists
of hardened, helically cut gear wheels. The gears are
housed by the timing gear case, which is installed to
the front of the engine.
The idler gear is supported with a ball bearing on the
shaft on the front face of the crankcase.
There are three main types of timing gear
assemblies:
• Narrow without PTO (Power Take-Off)
Figure 178. Narrow without PTO
A
C
B
D
A Camshaft gear
B Idler gear
C High pressure pump gear
D Crankshaft gear
• Broad with light duty PTO

3. 15 - Engine
51 - Timing Gear
00 - General
15 - 144 9813/3600-3 15 - 144
Figure 179. Broad with Light Duty PTO
A
E
C
B
D
A Camshaft gear
B Idler gear
C High pressure pump gear
D Crankshaft gear
E PTO gear
• Broad with heavy duty PTO
Figure 180. Broad with Heavy Duty PTO
A
E
CB
D
F
A Camshaft gear
B Idler gear
C High pressure pump gear
D Crankshaft gear
E PTO gear
F Smaller idler gear
If the engine is equipped with light duty PTO,
hydraulic pump is driven through a gear or a separate
drive unit.
In engines with heavy duty PTO, hydraulic pump or
compressor is driven through a small idler gear.

4. 15 - Engine
51 - Timing Gear
00 - General
15 - 145 9813/3600-3 15 - 145
Technical Data
Table 53. Timing Gear Data
Description Data
Tooth backlash 0.05 –0.25 mm
Maximum permissible
side wobble of gears
0.05 mm
Idle gear Slide bearing and 50.7
mm shaft length
Table 54. Timing Marks
Description
(1)
Data
On crankshaft gear 2 dots on tooth
On high pressure pump
gear
1 dot on notch
On camshaft gear 1 dot on notch
On idler gear
Against crankshaft gear
mark
1 dot on tooth
Against camshaft gear
mark
1 dot on tooth
Against high pressure
pump mark
2 dots on notch
(1) Timing marks on the gears are in alignment
when the 1st cylinder piston is at its TDC (Top Dead
Centre) between compression and power strokes.
Component Identification
Figure 181. Narrow without PTO
A
C
B
D
A Camshaft gear
B Idler gear
C High pressure pump gear
D Crankshaft gear
Figure 182. Broad with Light Duty PTO
A
E
C
B
D
A Camshaft gear
B Idler gear
C High pressure pump gear
D Crankshaft gear
E PTO (Power Take-Off) gear

5. 15 - Engine
51 - Timing Gear
00 - General
15 - 146 9813/3600-3 15 - 146
Figure 183. Broad with Heavy Duty PTO
A
E
CB
D
F
A Camshaft gear
B Idler gear
C High pressure pump gear
D Crankshaft gear
E PTO gear
F Smaller idler gear
Operation
All the gears are driven via the crankshaft gear as
follows:
• Camshaft gear-The camshaft is driven at half
crankshaft speed.
• High pressure fuel pump gear-The high
pressure fuel pump is driven via the camshaft
gear installed to the camshaft.
• Oil pump gear-The lubrication oil pump is driven
directly by the crankshaft gear.
• Power Take-Off (PTO)-driven by the crankshaft
gear via idler gear.
• Low Duty Power Take-Off (PTO) Gear (if
installed)-driven by the camshaft gear.
Timing
The engine must be `timed' so that the camshaft
operates the valves at the correct times relative to
the crankshaft position.
Valve timing is achieved by ensuring that the
camshaft drive gear is meshed to the crankshaft
gear at their correct angular positions.Refer to: PIL
15-00-00.

6. 15 - Engine
51 - Timing Gear
00 - General
15 - 147 9813/3600-3 15 - 147
Remove and Install
For removal and installation procedure of the timing
gear. Refer to: PIL 15-51-21.

7. 15 - Engine
51 - Timing Gear
03 - Crankshaft Gear
15 - 148 9813/3600-3 15 - 148
03 - Crankshaft Gear
Remove and Install
Remove
1. Get access to the crankshaft gear.
2. Apply the special puller (AGCO Part number
9052 48800) to the crankshaft gears.
Figure 184.
B
A
A Crankshaft gear
B Puller (AGCO Part number 9052 48800)
3. Pull off the crankshaft gears (x2).
4. Do not damage the crankshaft.
5. Clean the seat on the crankshaft with a wire
brush.
Install
1. Heat the new gears to specified temperature.
Temperature: 220 –250 °C ( 427.7 –481.6 °F)
2. Assemble the crankshaft gears onto the
crankshaft.
3. Make a note of the position of the key. Refer to
Figure 185.
4. Make sure that the aligning marks on the front
gear are visible.
5. Set the crankshaft key into the angular key slot.
Figure 185.
6. Allow the gears to cool.

8. 15 - Engine
51 - Timing Gear
06 - Camshaft Gear
15 - 149 9813/3600-3 15 - 149
06 - Camshaft Gear
Remove and Install
Refer to Camshaft- Remove and Install.Refer to: PIL
15-15-00.

9. 15 - Engine
51 - Timing Gear
21 - Front Case
15 - 150 9813/3600-3 15 - 150
21 - Front Case
Remove and Install
Remove
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. Drain the engine oil.
Refer to: PIL 15-21-00.
3. Remove the oil sump.
Refer to: PIL 15-45-00.
4. Remove the radiator.
Refer to: PIL 21-03-00.
5. Remove the cooling fan.
6. Remove the alternator.
Refer to: PIL 15-72-00.
7. Remove the belt tensioner and the belt.
8. If installed, remove the HVAC (Heating
Ventilation Air Conditioning) unit.
Refer to: PIL 12-03-00.
9. Remove the coolant pump.
Refer to: PIL 21-09-00.
10. Remove the crankshaft belt pulley and the
vibration damper.
11. Loosen the crankshaft nut by two turns with
the specified spanner (AGCO Part number 9024
55800).
Figure 186.
A
A Spanner (AGCO Part number 9024 55800)
12. Remove the hub from the crankshaft with
the specified puller (AGCO Part number 9201
82390).
12.1. Do not remove the nut completely at this
stage. The hub can be thrown dangerously
when the nut is loosened.
Figure 187.
B
B Puller (AGCO Part number 9201 82390)
13. Remove the camshaft speed sensor, hydraulic
pump drive unit lubrication pipe and the drive
unit.
14. Remove the front cover.
15. Make a note that the screws on the idler gear
shaft and the screws on the broad timing gear
are similar. Do not interchange them.

10. 15 - Engine
51 - Timing Gear
21 - Front Case
15 - 151 9813/3600-3 15 - 151
Figure 188.
D
C
C Idler gear shaft
D Broad timing gear
16. If necessary, remove the oil deflector ring from
the front end of the crankshaft.
17. If necessary, remove the HP (High Pressure)
pump.
Refer to: PIL 18-18-15.
17.1. If you do not remove the HP pump,
disconnect all electrical harnesses and the
pipes from the HP pump.
18. Remove the idler gear screw.
19. Remove the idler gear.
20. Remove the small idler gear.
21. Remove the camshaft.
22. If the cylinder head and the rocker assembly
is not removed, prevent the tappets from falling
down.
Refer to: PIL 15-15-00.
23. Remove the screws from the timing gear case.
24. Remove the timing gear case.
Refer to: PIL 15-51-21.
25. Remove the crankshaft front sealing ring from the
front case.
26. Make a note that the oil deflector ring is behind
the sealing ring.
Install
1. Clean all the parts thoroughly.
2. Apply specified sealant (AGCO Part number
8366 62735) on the timing gear case sealing
surfaces.
3. Install the timing gear case against the
crankcase.
4. Install the tension pins with the specified drift
(AGCO Part number 9025 98700).
Figure 189.
E
E Tension pin
5. Tighten the nuts and the bolts.
6. Lubricate the camshaft bearings and insert the
camshaft into the crankcase.
7. Release the push rods and the tappets.
8. Install the idler gear stud.
9. Make sure that the timing marks are in the correct
position.

11. 15 - Engine
51 - Timing Gear
21 - Front Case
15 - 152 9813/3600-3 15 - 152
Figure 190.
F
G
F Timing marks
G Front cover screw holes
10. Rotate the idler gear shaft so that the front cover
screw holes are vertically aligned.
11. Install the bolts and the washers.
12. Tighten the bolts to the correct torque value.
Torque: 180 N·m
13. Install the small idler gear.
14. Apply the locking compound on the screws.
15. Tighten the screw to the correct torque value.
Torque: 45 N·m
16. Install the HP pump and the gear wheel.
17. Make sure that the timing marks are in the correct
position.
18. Tighten the camshaft and the HP pump gear nut.
19. Check the tooth backlash.
19.1. Make sure that the backlash is as
specified.
Dimension: 0.05 –0.25 mm
Figure 191.
H
H Feeler gauge
20. If removed, install the oil deflector ring on the
front of the crankshaft.
21. Install the front cover.
22. Install the drive unit cover and the shaft to the
front cover.
23. Apply the specified sealant (AGCO Part number
8366 62735) on the timing gear case.
24. Install the timing gear case front cover.
25. Install the tension pin in its place.
26. Make a note that the sealing ring is under the idler
gear screws.
27. Install the drive unit rear bearing and the adaptor
plate.
28. Install the nuts and the bolts.
29. Install the protective plate into the seal location.
30. Install the crankshaft front seal with a suitable
drift (AGCO Part number 9103 94600).

12. 15 - Engine
51 - Timing Gear
21 - Front Case
15 - 153 9813/3600-3 15 - 153
Figure 192.
J
J Drift (AGCO Part number 9103 94600)
31. Check the condition of the conical surfaces on
the crankshaft and the hub.
32. Lubricate the seals and the sealing surface.
33. Lubricate the hub nut thread, rear surface and
the outer surface with Vaseline.
33.1. Do not use oil, it may run into the conical
surfaces.
34. Install the crankshaft hub.
35. Install the hub nut onto the crankshaft thread.
36. Tighten the hub nut the correct torque value.
Torque: 1,000 ± 100 N·m
37. Install the crankshaft belt pulley and the vibration
damper.
38. Install the coolant pump.
Refer to: PIL 21-09-00.
39. If removed, install the HVAC unit.
Refer to: PIL 12-03-00.
40. Install the belt tensioner and the belt.
41. Install the alternator.
Refer to: PIL 15-72-00.
42. Install the cooling fan.
43. Install the radiator.
Refer to: PIL 21-03-00.
44. Install the oil sump.
Refer to: PIL 15-45-00.
45. Fill the engine oil to the correct level.
Refer to: PIL 15-21-00.

13. 15 - Engine
54 - Flywheel
00 - General
15 - 156 9813/3600-3 15 - 156
Technical Data
Table 55. Flywheel Data
Description Data
Interference fit between
ring gear and flywheel
0.425 –0.6 mm
Before installation of the
ring gear, heat up to a
temperature of
150 –200 °C ( 301.8 –
391.7 °F)
Flywheel unbalance Maximum 1.0 Ncm
Maximum permissible
axial wobble of flywheel
clutch face, measured at
inner edge of the clutch
face on diameter 200
mm
0.06 mm
Component Identification
Figure 193.
2
1
1 Flywheel
2 Flywheel gear ring

14. 15 - Engine
54 - Flywheel
00 - General
15 - 157 9813/3600-3 15 - 157
Remove and Install
Remove
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the flywheel.
4. Remove the bolts and withdraw the flywheel from
the crankshaft hub.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Clean the contact surfaces on the crankshaft rear
flange and on the flywheel.
3. Use suitable studs as a guide when you install
the flywheel on the crankshaft rear flange.
4. Tighten the bolts to the correct torque value.
Torque: 150 N·m

15. 15 - Engine
54 - Flywheel
03 - Housing
15 - 158 9813/3600-3 15 - 158
03 - Housing
Introduction .................................................. 15-158
Remove and Install ..................................... 15-159
Introduction
The flywheel housing is installed at the rear end of
the crankcase. The seal for the crankshaft rear end
is placed in a bore in the housing. The starter motor
fixing point is installed in the flywheel housing.
The lower face of the flywheel housing functions
as a sealing surface for the oil sump gasket. This
means that the lower face of the crankcase must
be level with the flywheel housing. When you install
the flywheel housing, its position is determined by
tension pins.

16. 15 - Engine
54 - Flywheel
03 - Housing
15 - 159 9813/3600-3 15 - 159
Remove and Install
Remove
1. This procedure requires service parts. Make sure
that you have obtained the correct service parts
before you start.
2. Remove the flywheel.
Refer to: PIL 15-54-00.
3. Remove the bolts from the flywheel housing.
4. Separate the flywheel housing from the gear
case.
Install
1. Clean the sealing surfaces between the
crankcase and the flywheel housing.
2. Apply silicone sealant to the flywheel housing.
Refer to Figure 194.
Figure 194.
A
A Silicon sealant
3. Keep the flywheel housing in place.
4. Install the bolts.
5. Centre the housing with ARCO centering tool
number 9052 46400.
5.1. This is important for engines with a turbine
clutch.
6. Install the tension pins with a suitable drift.
7. Apply thread sealant to the bolts that are in
contact with oil or water.
8. Tighten the bolts to the specified torque value.
8.1. For inner ring socket head bolts
Torque: 80 N·m
8.2. For outer ring hexagonal bolts
Torque: 150 N·m

17. 15 - Engine
54 - Flywheel
09 - Gear Ring
15 - 160 9813/3600-3 15 - 160
09 - Gear Ring
Introduction .................................................. 15-160
Remove and Install ..................................... 15-161
Introduction
The ring gear cannot be turned around because its
teeth are chamfered and hardened on the starter
motor side.
If the ring gear is worn, it must be replaced.
Figure 195.

18. 15 - Engine
54 - Flywheel
09 - Gear Ring
15 - 161 9813/3600-3 15 - 161
Remove and Install
Remove
1. Get access to the gear ring.
2. Tap the gear ring at various points with a drift.
3. Remove the gear ring from the flywheel.
Install
1. Clean the flywheel contact face with a steel wire
brush.
2. Warm the gear ring to the specified temperature.
Temperature: 150 –200 °C ( 301.8 –391.7 °F)
3. Install the gear ring with the inner diameter
chamfer turned against the flywheel and the teeth
chamfer against the starter motor.
4. Allow the gear ring to cool freely.
4.1. Do not use coolant.

19. 15 - Engine
60 - Oil Pump
00 - General
15 - 165 9813/3600-3 15 - 165
Remove and Install
Remove
1. Drain the engine oil.
Refer to: PIL 15-21-00.
2. Remove the oil sump.
Refer to: PIL 15-45-00.
3. Disconnect the oil pump suction pipe and the
pressure pipe.
4. Remove the oil pump.
5. Collect any shims between the pump and the
crankcase.
Install
1. Install the oil pump.
2. Check the tooth backlash against the crankshaft
gear.
2.1. Make sure that the clearance is within the
specified limits.
Dimension: 0.05 –0.25 mm
2.2. If necessary, adjust the shims between the
pump body and the crankcase.
Figure 196. Backlash Check
2.3. Use a shim of the specified thickness only
(AGCO Part number 8360 07871).
2.4. Make a note that one shim increases or
decreases the backlash by the specified
value.
Dimension: 0.07 mm
2.5. Make sure that when you measure the tooth
backlash, the engine is the correct way up
as the crankshaft bearing clearance affects
the tooth backlash.
3. Connect the oil pump suction pipe and the
pressure pipe.
4. Install the oil sump.
Refer to: PIL 15-45-00.
5. Fill the engine oil to the correct level.
Refer to: PIL 15-21-00.
Table 57. Torque Values
Item Description Nm
A Nut 60

20. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

21. 15 - Engine
60 - Oil Pump
00 - General
15 - 166 9813/3600-3 15 - 166
Disassemble and Assemble
Remove
1. Remove the oil pump.
Refer to: PIL 15-60-00.
2. Remove the pump cover.
3. Discard the gasket.
4. Remove the gear on the axle.
5. Hold the pump gear across the teeth in a soft jaw
vice.
6. Loosen the drive gear nut.
7. Hit the end of the shaft with a soft hammer and
remove the gear wheel.
8. Pull out the drive shaft gear wheel.
9. Clean all the parts thoroughly.
10. Check the condition of the pump components for
wear and other damage.
11. Replace the damaged parts.
12. Replace all the seals.
13. The bearing points are provided with separate
bearing bushes. If you replace the bushes,
machine them to the specified size after
installation.
Dimension: 18 –18.018 mm
Install
1. Install the gear wheels to the pump body.
2. Install the cover with a new gasket.
3. Tighten the screws partially.
4. Rotate the pump shaft and tap the side of the
cover gently until it reaches the position in which
the shaft rotates most freely.
5. Tighten the screws and make sure that the shaft
still rotates freely.
6. Install the drive gear onto the shaft.
7. Apply threadsealer (AGCO Part number 8366
62736) onto the nut threads.
8. Install the washer and the nut.
9. Tighten the nut to the correct torque value.
Figure 197.
A
A Nut
10. Hold the oil pump in a vice.
11. Check the end float between the gear and the
pump body.
11.1. Make sure that the clearance is within the
specified limits.
Dimension: 0.03 –0.11 mm
11.2. If necessary, adjust the number of gaskets
between the cover and the pump body.
Figure 198. End Float Check
12. Install the oil pump.
Refer to: PIL 15-60-00.

22. 15 - Engine
63 - Mount
00 - General
15 - 172 9813/3600-3 15 - 172
Check (Condition)
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. Tilt the operator station.
3. Open the engine compartment cover.
Refer to: PIL 06-06-06.
4. Check the security of the bolts on the left and
right gearbox mounts.
5. Check the security of the bolts on the left and
right engine mounts.
Figure 201.
A
A
B
B
A Gearbox mount
B Engine mount

23. 15 - Engine
63 - Mount
00 - General
15 - 173 9813/3600-3 15 - 173
Remove and Install
You must remove and install the engine and the
gearbox together as a complete unit.
Remove
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. Remove the operator station.
Refer to: PIL 09-00-00.
3. Remove the engine.
4. Remove the bolts 3 from the gearbox and the
engine chassis mounts.
Figure 202.
BB
BA
BB
BA
BB
BB BA
BA Bolts 3 BB Mounts
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Clean the engine, gearbox and machine chassis
thoroughly.
3. Check the condition of the engine and gearbox
mounts. If necessary, replace any damaged
mounts.