service repair manual

1. SERVICE MANUAL
FASTRAC (AGRICULTURAL TRACTOR)
8290, 8330
EN - 9813/5000 - ISSUE 2 - 08/2016
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2016 © 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 and Options
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 - Brakes
25 - Steering System
27 - Driveline
28 - Suspension
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

2. 15 - Engine
36 - Piston
00 - General
15 - 103 9813/5000-2 15 - 103
00 - General
Introduction .................................................. 15-103
Technical Data ............................................. 15-104
Component Identification ............................. 15-105
Operation ..................................................... 15-106
Check (Condition) ........................................ 15-107
Remove and Install ..................................... 15-107
Introduction
The piston is acted upon by the pressure of the
expanding combustion gases in the combustion
chamber space at the top of the cylinder. This force
then acts downwards through the connecting rod and
on to the crankshaft.
The pistons are cast from aluminium alloys for
increased strength and improved fatigue life.
The connecting rod is attached to the piston by a
swivelling piston pin. This pin is mounted within the
piston, The pin itself is of hardened steel and is fixed
in the piston, but free to move in the connecting rod.
The pins are prevented from moving sideways and
the ends of the pin digging into the cylinder wall by
circlips.

3. 15 - Engine
36 - Piston
00 - General
15 - 104 9813/5000-2 15 - 104
Technical Data
Table 43. Piston Data
Description Data
Piston diameter at
15mm from lower edge
110.863–110.877mm
Pin bore in piston 40.003–40.009mm
Piston pin diameter 43.994–40mm
Width of the piston ring grooves
1st groove Wedge shaped ring
2nd groove 2.52–2.54mm
3rd groove 4.04–4.06mm
Side clearance of piston rings in their grooves
1st ring Wedge shaped ring
2nd ring 0.03–0.062mm
3rd ring 0.05–0.082mm
Reject limit 0.15mm
Piston ring height (in direction of cylinder)
1st ring Wedge shaped ring
2nd ring 2.478–2.49mm
3rd ring 3.975–3.99mm
Piston ring gap (with piston installed in cylinder)
1st ring (Wedge shaped
ring)
0.35–0.5mm
2nd ring 0.6–0.8mm
3rd ring 0.3–0.6mm
Reject limit for 1st and
3rd ring
1mm
Reject limit for 2nd ring 1.3mm
Maximum permissible
weight difference be-
tween pistons in same
engine
0.025kg
Piston must be heated up to 100°C (211.9°F) be-
fore you install the gudgeon pin.

4. 15 - Engine
36 - Piston
00 - General
15 - 105 9813/5000-2 15 - 105
Component Identification
Figure 150.
120°
120°
120°
Y
X
C
TOP
2A
3B
4
4a
TOP
TOP
1
7
6
7
5
1 Piston 2 Piston ring - compression No.1
3 Piston ring - compression No.2 4 Piston ring - oil control ring
4a Spiral wire - oil control ring 5 Connecting rod
6 Piston pin 7 Retaining circlip (x2)
X Connecting rod - longest side Y Cast boss - piston

5. 15 - Engine
36 - Piston
00 - General
15 - 106 9813/5000-2 15 - 106
Operation
The groove around the diameter of the upper main
bearing shells allows oil transfer to an oil jet located
in the crankcase bearing saddle. Jets are installed at
the main bearing positions.
The jets spray oil directly to the under side of the
pistons effectively transferring heat away from the
top of the pistons. Oil spray also enters the small end
bearing bushes via a feed hole on the top of each
connecting rod.
Note: On turbocharged engines additional J-jets are
installed. Oilways connect the J-shaped jets fixed to
the crankcase at the underside of each cylinder bore.
Figure 151.
2
6
1 1
2
4
5
3
1 Groove 2 Oil jet
3 Pistons 4 Bearing bushes
5 Crankshaft 6 J shaped jets

6. 15 - Engine
36 - Piston
00 - General
15 - 107 9813/5000-2 15 - 107
Check (Condition)
1. Check the piston for signs of damage and
excessive wear. Measure the piston skirt
diameter, piston pin bore and the clearance in
the piston ring grooves to confirm they are within
service limits. Refer to Piston, Technical Data
(PIL 15-36).
2. Check the piston pin for signs of damage and
excessive wear. Measure the pin diameter to
confirm it is within service limits. Refer to Piston,
Technical Data (PIL 15-36).
The connecting rod small end bearing bush is not
renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
Remove and Install
Remove
1. Remove the oil sump. Refer to (PIL 15-42).
2. Remove the oil inlet and pressure pipes.
3. Remove the cylinder head. Refer to (PIL 15-06).
4. Remove any soot in the cylinder bore.
5. If the turning edge is clearly marked, smooth it
down carefully with a scraper.
6. Remove the big end bearing caps and bearing
shells.
7. Place the shells in sequence.
8. Push up the piston and the connecting rod with
the shaft of a hammer or similar wooden tool.
9. Remove the piston pin snap rings.
10. Push out the pin.
11. If the piston pin does not move under thumb
pressure, the piston should be heated to the
specified temperature.
Temperature: 100°C (211.9°F)
Install
1. Place the connecting rod inside the piston.
2. Push the piston pin into place.
3. The weight class letter should be on the side of
the camshaft.
4. The arrow on the piston points towards the front
end of the engine.
5. Instal the piston pin circlips.
6. Make sure that the circlips are pressed correctly
into the grooves.
7. The circlip ends must point upwards.

7. 15 - Engine
36 - Piston
00 - General
15 - 108 9813/5000-2 15 - 108
Figure 152.
8. Make sure that the bearing locations are clean.
9. Place the bearing shells in the connecting rod
and the bearing cap.
10. Make a note of the position of the bearing shells.
11. Lubricate the piston, piston rings and the cylinder
bore.
12. Make sure that the piston ring gaps are spread
around the piston.
13. Use a piston ring strap or AGCO special tool
number 9201 85840 to install the piston.
14. Make sure that the direction of the arrow on the
piston shows forward.
15. Lubricate the big end bearing journal and the
bearing shells.
16. Push the piston down.
17. Install the bearing cap so that the notches for the
guide lugs are in the same side.
18. Tighten the connecting rod screws to the correct
torque value.
18.1.First tighten to the specified torque value.
Torque: 40N·m
18.2.Tighten to the specified torque value.
Torque: 80N·m
18.3.Tighten by the specified degrees.
Angle: 90°
19. Check that the connecting rod has sufficient end
float on the big-end bearing journal.

8. 15 - Engine
36 - Piston
03 - Piston Ring
15 - 109 9813/5000-2 15 - 109
03 - Piston Ring
Introduction .................................................. 15-109
Remove and Install ..................................... 15-110
Introduction
Gas sealing inside the piston is achieved by the use
of piston rings. The rings are loosely installed into
grooves in the piston. The rings are split at a point in
the rim, to allow them to press against the cylinder
with a light spring pressure.
Two types of ring are used:
- Upper rings have solid faces and provide gas
sealing
- Lower rings have narrow edges and have a U-
shaped profile, to act as oil scrapers.

9. 15 - Engine
36 - Piston
03 - Piston Ring
15 - 110 9813/5000-2 15 - 110
Remove and Install
Remove
1. Remove the piston rings with the piston ring
pliers (AGCO Part number 9052 46900).
2. Do not open the rings more than necessary.
Check Condition
1. Clean the piston ring grooves.
2. Measure the piston ring clearance with a feeler
gauge.
2.1. Make sure that the piston ring clearance
does not exceed the specified value.
Dimension: 0.15mm
Figure 153.
2.2. Determine whether too large a clearance is
due to worn rings or a worn groove.
2.3. Change any worn parts.
3. Measure the piston ring gap with a feeler gauge.
3.1. Push one piston ring at a time into the
cylinder bore.
3.2. Make sure that the piston ring gap does not
exceed the rejection value. Refer to Piston,
Technical Data (PIL 15-36).
Figure 154.
E
E Piston ring end gap
Install
1. If the rings are to be used again, make sure that
they are installed in the same groove.
2. Install the piston rings on to the piston with the
piston ring pliers.
3. Make sure that the TOP or the manufacturer's
designation on the piston ring faces upwards.

10. 15 - Engine
42 - Rocker and Fittings
00 - General
15 - 115 9813/5000-2 15 - 115
00 - General
Introduction .................................................. 15-115
Technical Data ............................................. 15-116
Component Identification ............................. 15-117
Operation ..................................................... 15-118
Check (Condition) ........................................ 15-119
Introduction
The rocker assembly is an indirect valve actuating
system consisting of rocker arms and a shaft.
The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
movement at the poppet valve to open it. One end is
raised and lowered by a rotating lobe of the camshaft
via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.

11. 15 - Engine
42 - Rocker and Fittings
00 - General
15 - 116 9813/5000-2 15 - 116
Technical Data
Table 44. Rocker Arm Data
Description Data
Rocker arm shaft diame-
ter
24.97–24.99mm
Diameter of rocker arm
bore
25–25.021mm
Free length of rocker
arm spring
88mm
Spring pressure when
spring is compressed to
a length of 66mm
75–95N
Table 45. Tappet and Push Rod Data
Description Data
Outside diameter of tap-
pet
29.939–29.96mm
Diameter of tappet bore
in crankcase
30–30.043mm
Maximum permissi-
ble push rod deflection
(when free)
0.4mm
Overall length of push
rod
286–287.3mm

12. 15 - Engine
42 - Rocker and Fittings
00 - General
15 - 117 9813/5000-2 15 - 117
Component Identification
Figure 155.
3
1
2
2
2
2
2
2
2
2
2
2
8
7
4
5
6
9
10
1 Rocker assembly 2 Rocker shaft fixing bolts (x11)
3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x11)
5 Oil feed pedestal (x1) 6 Rockers - exhaust (x6)
7 Rockers - inlet (x6) 8 Wave washers (x6)
9 Bridge pieces (x12) 10 Push rods (x12)

13. 15 - Engine
42 - Rocker and Fittings
00 - General
15 - 118 9813/5000-2 15 - 118
Operation
When the camshaft lobe raises the outside of the
rocker arm, the inside presses down on the valve
stem to open the valve. When the outside of the
rocker arm is permitted to return due to the camshafts
rotation, the inside rises to allow the valve spring to
close the valve.
Figure 156.
1 Oil feed from main gallery 2 Small transfer gallery
3 Shaft pedestal 4 Rocker shaft fixing bolt hole
5 Centre rocker shaft drilling 6 Cross drillings
7 Rocker pivot bushes 8 Cross drilling
9 Groove
Lubrication
Oil is fed from the main gallery via a drilling which
passes up through the crankcase and the cylinder
head to a small transfer gallery under the rocker
shaft pedestal. The oversize rocker shaft fixing bolt
hole allows oil to pass into a drilling in the centre of
the rocker shaft. Further cross drillings transfer oil
to each of the rocker pivot bushes. A cross drilling
in each rocker transfers oil to the top of the rocker
where it flows by gravity along a groove to the rocker
tip.

14. 15 - Engine
42 - Rocker and Fittings
00 - General
15 - 119 9813/5000-2 15 - 119
Check (Condition)
1. Check the condition of the valve tappets.
2. Check the contact surface of the valve tappets
against the camshaft.
3. Discard any worn out or damaged tappets.
4. Roll the push rod on a surface table to check the
straightness.
Figure 157.
B
A
A Push rod
B Surface table
5. Check the spherical surfaces at the ends of the
push rods.
6. Make a note of the push rod length, they should
be within the specified values. Refer to Rocker
and Fittings, Technical Data (PIL 15-42).
7. Disassemble the rocker and fittings assembly.
Refer to (PIL 15-42).
8. Clean the rocker and fittings assembly. Refer to
(PIL 15-42).
9. Check the rocker shaft for wear.
10. Make sure that the oil ways are clean.
11. Make sure that the diameter of the rocker arm
bore is within the specified limits.
Dimension: 25–25.021mm
12. Replace any worn or damaged rocker arms.
Figure 158.
C
C Rocker arm bore diameter (25–25.021mm)
13. If necessary, grind the rocker arm valve contact
surface to the correct the shape.
13.1.Do not grind more than necessary. Make a
note that the hardened layer is thin.
14. Install the plug to the other end of the rocker arm
shaft.
15. Lubricate the rocker shaft.
16. Assemble the rocker and fittings assembly. Refer
to (PIL 15-42).
17. Make a note of the correct position of the rocker
shaft and the bearing brackets.
18. Install the plug at the other end.
19. Tighten the plug to the correct torque value.
Figure 159.
20. Install the connecting parts onto the valves in
position.

15. 15 - Engine
42 - Rocker and Fittings
00 - General
15 - 120 9813/5000-2 15 - 120
Figure 160.
21. Install the valve mechanism.
22. Make sure that the right end clearance is as
specified for the levers at the end.
Dimension: 0.05–0.2mm
Figure 161.
D
E
F
D Nut
E End clearance (0.05–0.2mm)
F End plug
23. Tighten the fasteners to the correct torque value.
Table 46. Torque Values
Item Description Nm
D Nut 45
F End plug 25

16. 15 - Engine
45 - Oil Sump
00 - General
15 - 125 9813/5000-2 15 - 125
00 - General
Introduction .................................................. 15-125
Technical Data ............................................. 15-126
Component Identification ............................. 15-126
Remove and Install ..................................... 15-127
Introduction
The lubrication system distributes oil around the
engine by a system of galleries and drillings in the
crankcase and cylinder head. The oil lubricates and
seals the moving parts of the engine, reducing friction
and wear. In addition the oil plays an important role in
cooling the engine by carrying heat from the engine
to the cooler. The lubrication of the gears in the gear
housing, the upper end of the connecting rods and
the pistons is mainly achieved 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 3bar (43.5psi).
Oil is drawn from the oil sump by the integral oil
pump. Refer to (PIL 15-60).
The oil passes from the outlet side of the pump
through a relief valve which limits the maximum oil
pressure by venting oil back to the inlet side of the
pump.
From the pump the oil passes through the oil cooler
and filter, refer to (PIL 15-69 and PIL 15-21).
After cooling and filtering, the oil passes into the
main oil gallery. An oil pressure switch senses the
oil pressure. From the main gallery oil is delivered,
through drillings, to the crankshaft main bearings,
rocker assembly, camshaft and timing gears. Note
that the drillings are through the crankcase and
cylinder head.
When the high pressure oil has passed through the
bearings it reverts to sump pressure and splash
lubricates the internal components such as rocker
tips, cam lobes and timing gear teeth. Gravity drains
the oil through drains into the cylinder head and
crankcase, back into the oil sump. A drain slot allows
the oil to drain from the timing case back to the oil
sump.
The engine is installed with the closed CCV
(Crankcase Ventilation) system. There is Super
Impactor type CCV system with boost air. CCV
system is maintenance free.

17. 15 - Engine
45 - Oil Sump
00 - General
15 - 126 9813/5000-2 15 - 126
Technical Data
Table 47. Oil Sump Data
Description Data
Drain plug torque 80N·m
Table 48. Oil Sump Capacity
Oil Sump Part
Number (AG-
CO Power)
Minimum Oil
Capacity
Maximum Oil
Capacity
8363 47308 20L 25.5L
8363 36229 21.5L 25.5L
8370 74007 17L 22L
8370 84152 19L 24L
8370 84394 16L 19L
8368 73817 16L 19L
8368 74808 17L 20L
8368 84674 17L 20L
8368 84621 16.8L 19.5L
8368 73994 21L 25L
8368 74002 20L 24L
8368 73779 16.5L 21.5L
Component Identification
Figure 162.
A
B
A Oil sump
B Gasket

18. 15 - Engine
45 - Oil Sump
00 - General
15 - 127 9813/5000-2 15 - 127
Remove and Install
Before Removal
1. Make sure that the engine is safe to work on.
If the engine has been running, make sure the
engine has cooled sufficiently before you start.
2. Drain the engine oil. Refer to (PIL 15-21).
3. Remove the front axle. Refer to (PIL 27-20).
Removal
1. Remove the fixing bolts and remove the oil sump
from the engine. The oil sump may be difficult to
remove due to adhesion of sealing compound.
If necessary, carefully lever the mating flanges
apart. Do not use excessive force, the oil sump
could be damaged. Be sure to retrieve the oil pick
up seal.
2. Use a gasket removal compound, carefully
remove all traces of sealing compound from the
oil sump and engine mating faces. Do not allow
the sealing compound to enter the engine.
3. Use a suitable degreasing agent to thoroughly
clean the oil sump.
Figure 163.
A
B
A Oil sump
B Gasket
Installation
1. Lightly smear the new seal with oil and install into
the case as shown.
2. Install the oil sump gasket with the silicone
stripes against the crankcase.
3. Take care not to damage the oil pick up seal when
you install the oil sump. Damage to the seal could
cause a drop in oil pressure and subsequently
damage to the engine.
4. Locate the oil sump on the engine.
5. Install the bolts and tighten the bolts to the correct
torque value.
After Replacing
1. Refill the engine with the recommended engine
oil. Refer to (PIL 75-03).
2. Start the engine and check for oil leaks.

19. 15 - Engine
45 - Oil Sump
12 - Gasket
15 - 128 9813/5000-2 15 - 128
12 - Gasket
Remove and Install
Remove
1. Remove the oil sump from the engine. Refer to
(PIL 15-45).
2. Remove and discard the gasket from the oil
sump.
Figure 164.
A
B
A Oil sump
B Gasket
Install
1. Install the new gasket on the crankcase.
2. Make sure that the silicon strips on the gasket
face the crankcase.
3. Install the oil sump on the engine. Refer to (PIL
15-45).

20. 15 - Engine
51 - Timing Gear
15 - 129 9813/5000-2 15 - 129
51 - Timing Gear
Contents Page No.
15-51-00 General ......................................................................................................................... 15-131
15-51-03 Crankshaft Gear ........................................................................................................... 15-136
15-51-06 Camshaft Gear ............................................................................................................. 15-137
15-51-21 Front Case ................................................................................................................... 15-138

21. 15 - Engine
51 - Timing Gear
00 - General
15 - 131 9813/5000-2 15 - 131
00 - General
Introduction .................................................. 15-131
Technical Data ............................................. 15-133
Component Identification ............................. 15-133
Operation ..................................................... 15-134
Remove and Install ..................................... 15-135
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 165. 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

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23. 15 - Engine
51 - Timing Gear
00 - General
15 - 132 9813/5000-2 15 - 132
Figure 166. 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 167. 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.

24. 15 - Engine
51 - Timing Gear
00 - General
15 - 133 9813/5000-2 15 - 133
Technical Data
Table 49. Timing Gear Data
Description Data
Tooth backlash 0.05–0.25mm
Maximum permissible
side wobble of gears
0.05mm
Idle gear Slide bearing and
50.7mm shaft length
Table 50. 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 168. Narrow without PTO
A
C
B
D
A Camshaft gear
B Idler gear
C High pressure pump gear
D Crankshaft gear
Figure 169. 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

25. 15 - Engine
51 - Timing Gear
00 - General
15 - 134 9813/5000-2 15 - 134
Figure 170. 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).