JCB 8290, 8330 FASTRAC (AGRICULTURAL TRACTOR) Service Repair Manual Instant Download (From 1351000 To 1359999)

1
Foreword
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
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
00 - General
Introduction
Introduction .....................................
............. 15-103 Technical Data
.............................................
15-104 Component Identification
............................. 15-105 Operation
..................................................
... 15-106 Check (Condition) .....................
................... 15-107 Remove and Install
..................................... 15-107
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.
15 - 103
3
15 - Engine 36 - Piston 00 - General
Technical Data Table 43. Piston Data
Description Data
Piston diameter at 15mm from lower edge 110.863110.877mm
Pin bore in piston 40.00340.009mm
Piston pin diameter 43.99440mm
Width of the piston ring grooves Width of the piston ring grooves
1st groove Wedge shaped ring
2nd groove 2.522.54mm
3rd groove 4.044.06mm
Side clearance of piston rings in their grooves Side clearance of piston rings in their grooves
1st ring Wedge shaped ring
2nd ring 0.030.062mm
3rd ring 0.050.082mm
Reject limit 0.15mm
Piston ring height (in direction of cylinder) Piston ring height (in direction of cylinder)
1st ring Wedge shaped ring
2nd ring 2.4782.49mm
3rd ring 3.9753.99mm
Piston ring gap (with piston installed in cylinder) Piston ring gap (with piston installed in cylinder)
1st ring (Wedge shaped ring) 0.350.5mm
2nd ring 0.60.8mm
3rd ring 0.30.6mm
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 100C (211.9F) be- fore you install the gudgeon pin. Piston must be heated up to 100C (211.9F) be- fore you install the gudgeon pin.
15 - 104
4
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5
15 - Engine 36 - Piston 00 - General
Component Identification
Figure 150.
2
A
X
TOP
5
3
B
TOP
C
4a TOP
1
7
4
6
7
120
120
Y
120
1 Piston 3 Piston ring - compression
No.2 4a Spiral wire - oil control ring 6 Piston
pin X Connecting rod - longest side
2 Piston ring - compression No.1 4 Piston ring -
oil control ring 5 Connecting rod 7 Retaining
circlip (x2) Y Cast boss - piston
6
15 - Engine 36 - Piston 00 - General
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.
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.
The jets spray oil directly to the under side of
the pistons effectively transferring heat away
from the
Figure 151.
3 4
2
1
1
6
2
5
1 Groove 3 Pistons 5 Crankshaft
2 Oil jet 4 Bearing bushes 6 J shaped jets
7
15 - Engine 36 - Piston 00 - General
Check (Condition)
Remove and Install

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).

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.

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.

• Push out the pin.
• If the piston pin does not move under thumb
  pressure, the piston should be heated to the
  specified temperature.
• Temperature 100C (211.9F)
• Install
• Place the connecting rod inside the piston.
• Push the piston pin into place.
• The weight class letter should be on the side of
  the camshaft.
• The arrow on the piston points towards the front
  end of the engine.
• Instal the piston pin circlips.
• Make sure that the circlips are pressed correctly
  into the grooves.
• The circlip ends must point upwards.

8
15 - Engine 36 - Piston 00 - General
Figure 152.

• Make sure that the bearing locations are clean.
• Place the bearing shells in the connecting rod
  and the bearing cap.
• Make a note of the position of the bearing
  shells.
• Lubricate the piston, piston rings and the
  cylinder bore.
• Make sure that the piston ring gaps are spread
  around the piston.
• Use a piston ring strap or AGCO special tool
  number 9201 85840 to install the piston.
• Make sure that the direction of the arrow on the
  piston shows forward.
• Lubricate the big end bearing journal and the
  bearing shells.
• Push the piston down.
• Install the bearing cap so that the notches for
  the guide lugs are in the same side.
• Tighten the connecting rod screws to the correct
  torque value.
• First tighten to the specified torque value.
  Torque 40Nm
• Tighten to the specified torque value. Torque
  80Nm
• Tighten by the specified degrees. Angle 90
• Check that the connecting rod has sufficient end
  float on the big-end bearing journal.

9
15 - Engine 36 - Piston 03 - Piston Ring
03 - Piston Ring
Introduction
Introduction .....................................
............. 15-109 Remove and Install
..................................... 15-110
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.

10
15 - Engine 36 - Piston 03 - Piston Ring
Remove and Install
Figure 154.

• Remove
• Remove the piston rings with the piston ring
  pliers (AGCO Part number 9052 46900).
• Do not open the rings more than necessary.
• Check Condition

E

1. Clean the piston ring grooves.
2. Measure the piston ring clearance with a feeler
   gauge.
3. Make sure that the piston ring clearance does
   not exceed the specified value.

E Piston ring end gap
Dimension 0.15mm Figure 153.
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.

• Determine whether too large a clearance is due
  to worn rings or a worn groove.
• Change any worn parts.
• Measure the piston ring gap with a feeler gauge.
• Push one piston ring at a time into the cylinder
  bore.
• Make sure that the piston ring gap does not
  exceed the rejection value. Refer to Piston,
  Technical Data (PIL 15-36).

11
15 - Engine 42 - Rocker and Fittings 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-115 Technical Data
.............................................
15-116 Component Identification
............................. 15-117 Operation
..................................................
... 15-118 Check (Condition) .....................
................... 15-119
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.
15 - 115
12
15 - Engine 42 - Rocker and Fittings 00 - General
Technical Data Table 44. Rocker Arm Data
Description Data
Rocker arm shaft diame- ter 24.9724.99mm
Diameter of rocker arm bore 2525.021mm
Free length of rocker arm spring 88mm
Spring pressure when spring is compressed to a length of 66mm 7595N
Table 45. Tappet and Push Rod Data
Description Data
Outside diameter of tap- pet 29.93929.96mm
Diameter of tappet bore in crankcase 3030.043mm
Maximum permissi- ble push rod deflection (when free) 0.4mm
Overall length of push rod 286287.3mm
15 - 116
13
15 - Engine 42 - Rocker and Fittings 00 - General
Component Identification
Figure 155. 3 2 2 2 2
2
2
2
2
5
2
2
1
9
8
10 6 7 4
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)
15 - 117
14
15 - Engine 42 - Rocker and Fittings 00 - General
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 3 Shaft pedestal 5
Centre rocker shaft drilling 7 Rocker pivot
bushes 9 Groove
2 Small transfer gallery 4 Rocker shaft fixing
bolt hole 6 Cross drillings 8 Cross drilling
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.
15 - 118
15
15 - Engine 42 - Rocker and Fittings 00 - General
Check (Condition)
Figure 158.

• Check the condition of the valve tappets.
• Check the contact surface of the valve tappets
  against the camshaft.
• Discard any worn out or damaged tappets.
• Roll the push rod on a surface table to check the
  straightness.
• Figure 157.

• C
• C Rocker arm bore diameter (2525.021mm)
• If necessary, grind the rocker arm valve contact
  surface to the correct the shape.
• Do not grind more than necessary. Make a note
  that the hardened layer is thin.
• Install the plug to the other end of the rocker
  arm shaft.
• Lubricate the rocker shaft.
• Assemble the rocker and fittings assembly. Refer
  to (PIL 15-42).
• Make a note of the correct position of the rocker
  shaft and the bearing brackets.
• Install the plug at the other end.
• Tighten the plug to the correct torque value.
• Figure 159.

B
A

• Push rod
• Surface table
• Check the spherical surfaces at the ends of the
  push rods.
• 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).
• Disassemble the rocker and fittings assembly.
  Refer to (PIL 15-42).
• Clean the rocker and fittings assembly. Refer to
  (PIL 15-42).
• Check the rocker shaft for wear.

• Make sure that the oil ways are clean.
• Make sure that the diameter of the rocker arm
  bore is within the specified limits.
• Dimension 2525.021mm
• Replace any worn or damaged rocker arms.

20. Install the connecting parts onto the valves
in position.
15 - 119
16
15 - Engine 42 - Rocker and Fittings 00 - General
Figure 160.
Table 46. Torque Values
Item Description Nm
D Nut 45
F End plug 25

• Install the valve mechanism.
• Make sure that the right end clearance is as
  specified for the levers at the end.
• Dimension 0.050.2mm
• Figure 161.
• D

F

• E
• Nut
• End clearance (0.050.2mm)
• End plug
• 23. Tighten the fasteners to the correct torque
  value.

15 - 120
17
15 - Engine 45 - Oil Sump 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-125 Technical Data
.............................................
15-126 Component Identification
............................. 15-126 Remove and
Install .....................................
15-127
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.
15 - 125
18
15 - Engine 45 - Oil Sump 00 - General
Technical Data
Component Identification
Figure 162.
Table 47. Oil Sump Data
Description Data
Drain plug torque 80Nm
B
A
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

1. Oil sump
2. Gasket

15 - 126
19
15 - Engine 45 - Oil Sump 00 - General
Remove and Install

1. Locate the oil sump on the engine.
2. Install the bolts and tighten the bolts to the
   correct torque value.

Before Removal
After Replacing

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).

1. Refill the engine with the recommended engine
   oil. Refer to (PIL 75-03).
2. Start the engine and check for oil leaks.

• Removal
• 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.
• 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.
• Use a suitable degreasing agent to thoroughly
  clean the oil sump.
• Figure 163.
• B
• A

• Oil sump
• Gasket
• Installation
• Lightly smear the new seal with oil and install
  into the case as shown.
• Install the oil sump gasket with the silicone
  stripes against the crankcase.
• 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.

15 - 127
20
15 - Engine 45 - Oil Sump 12 - Gasket

• 12 - Gasket
• Remove and Install
• Remove
• Remove the oil sump from the engine. Refer to
  (PIL 15-45).
• Remove and discard the gasket from the oil sump.
• Figure 164.
• B
• A

• Oil sump
• Gasket
• Install
• Install the new gasket on the crankcase.
• Make sure that the silicon strips on the gasket
  face the crankcase.
• Install the oil sump on the engine. Refer to (PIL
  15-45).

15 - 128
21
15 - Engine 51 - Timing Gear
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
15 - 129
22
15 - Engine 51 - Timing Gear 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-131 Technical Data
.............................................
15-133 Component Identification
............................. 15-133 Operation
..................................................
... 15-134 Remove and Install ....................
................. 15-135
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
• C
• A
• B
• D

• Camshaft gear
• Idler gear
• High pressure pump gear
• Crankshaft gear
• Broad with light duty PTO

15 - 131
23
15 - Engine 51 - Timing Gear 00 - General
Figure 166. Broad with Light Duty PTO
In engines with heavy duty PTO, hydraulic pump or
compressor is driven through a small idler gear.
C
E A B D

• Camshaft gear
• Idler gear
• High pressure pump gear
• Crankshaft gear
• PTO gear
• Broad with heavy duty PTO
• Figure 167. Broad with Heavy Duty PTO

C
B
A
E F
D

• Camshaft gear
• Idler gear
• High pressure pump gear
• Crankshaft gear
• PTO gear
• Smaller idler gear
• If the engine is equipped with light duty PTO,
  hydraulic pump is driven through a gear or a
  separate drive unit.

15 - 132
24
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15 - Engine 51 - Timing Gear 00 - General
Technical Data
Component Identification
Figure 168. Narrow without PTO
Table 49. Timing Gear Data
Description Data
Tooth backlash 0.050.25mm
Maximum permissible side wobble of gears 0.05mm
Idle gear Slide bearing and 50.7mm shaft length
C
A
Table 50. Timing Marks
B
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 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
D

• Camshaft gear
• Idler gear
• High pressure pump gear
• Crankshaft gear
• Figure 169. Broad with Light Duty PTO

(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.
C
E A B D

1. Camshaft gear
2. Idler gear
3. High pressure pump gear
4. Crankshaft gear
5. PTO (Power Take-Off) gear

15 - 133
26
15 - Engine 51 - Timing Gear 00 - General
Operation
Figure 170. Broad with Heavy Duty PTO
All the gears are driven via the crankshaft gear
as follows
C
B
A

• 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.

E
F
D
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).

1. Camshaft gear
2. Idler gear
3. High pressure pump gear
4. Crankshaft gear
5. PTO gear
6. Smaller idler gear

15 - 134
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available for immediate download. https//www.ebo
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