t4 hitech 00-02

00

General

01

Engine

02

Axles

03

Steering system

04

Drive train system

05

Brake system

06

Compressed air system

07

Hydraulic system

08

Electrical system

09

Cab

10

Air conditioning and heating system

11

Chassis

14 15 FI-44200 Suolahti Finland +358 20 45501 www.valtra.com

Implement drive system

Implement lift system

18

Diagrams

21

Special tools

Ref no 39 276 21 2

ENGLISH Copyright © 2016 by Valtra Inc. All rights reserved.

To the reader The Workshop manual is intended to be a practical reference source to be used in workshop. The repair instructions in the manual are based on methods which have been worked out in practice during normal workshop conditions and which are based on the use of special tools from the manufacturer when stated in the instructions. The manual also contains descriptions of the design and function of the components. Detailed maintenance instructions can be found in Operator’s manual. Wiring diagrams can be found in a separate publication for wiring diagrams. The Workshop manual is divided into groups (00–21) following the spare parts catalogue numbering. Some spare parts catalogue groups have been omitted as unnecessary. Due to the continual development of the products, the content of this manual may not always correspond to the new product. Therefore, we retain the right to make alterations without prior notification. Use only genuine AGCO Parts spare parts for optimum performance. Certain operations should be carried out with the aid of special tools designed by Valtra.

Tractor information

00 General Software

Repair

Maintenance

Tractor information

Model

Page

T4 HiTech

1

Technical specifications..................................................................................1 Dimensions................................................................................................ 1 Masses...................................................................................................... 3 Maximum permissible axle loading............................................................3 Tyres..........................................................................................................3 Construction....................................................................................................4 Automation configuration................................................................................ 6 Identification sticker........................................................................................ 8

Tractor information 21.5.2015

Model

Page

T4 HiTech

1

830

9 5 8 0 3

10 6 3 0 2 2

7

4

0 0 6

0 6 5

3 9 5

1 476 2995

5

8

3825

1315 5140

2

765

2 5 4

3 1 1

R893

1 R8 3 590

1421 1483

GUID-A57A4F49-D5E2-44E2-95E2-8CC7D0FDD4A1

1. Ground level 2. Front linkage

NOM front tyre radius (mm)

Rear tyresize

540/65R28

706.5

650/65R38

905.5

420/85R28

712.5

520/85R38

924.5

Front tyresize

440/80R28

SRI (mm)

675

SRI (mm)

707.5

540/80R38

480/70R28

710.5

580/70R38

913.5

16.9R28

710

20.8R38

917.5

540/65R30

732

650/65R42

745.5

650/75R38

700 600/65R28 Table continued on next page

875

NOM rear tyre radius (mm)

914.5

956.5 925 970


Model

Page

T4 HiTech

2

480/70R30

739

620/70R42

967.5

600/60R30

746.5

710/60R42

956

600/65R28

745.5

710/70R38

979.5

From the midpoint of the rear axle to the cab roof (mm)

Height to the roof (mm)

2205/2269 1) 1)

3130/3194 1)

With Skyview roof.

1

5

6

2 3

7

4

8

GUID-6AA74368-986C-4C7C-AEF8-54008C33E92E

(mm)

2280 (standard mudguards) 2550 (wide mudguards)

Front tyre size

NOM front tyre width (mm)

Track width front, min/max (mm)

Min/max (mm)

Rear tyre size

NOM rear tyre width (mm)

Track width rear, min/max (mm)

Min/max (mm)

540/65R28

550

1854/1935

420/85R28

418

1835/2030

2404/2485

650/65R38

645

1808/1850

2453/2495

2253/2448

520/85R38

516

1612/2012

440/80R28

441

2128/2528

1854/1906

2295/2347

540/80R38

550

1676/1850

480/70R28

2226/2400

479

1835/2030

2314/2509

580/70R38

577

1714/1910

2291/2487

16.9R28

429

1835/2030

2264/2459

20.8R38

528

1612/2012

2140/2540

540/65R30

550

1854/1935

2404/2485

650/65R42

645

1808/1850

2453/2495

600/65R28

591

1915/1935

2506/2526

650/75R38

645

1780/1830

2425/2475

Table continued on next page

Min (mm)

2530 (standard mirrors)


Model

Page

T4 HiTech

3

480/70R30

479

1935/2030

2414/2509

620/70R42

625

1713/1910

2338/2535

600/60R30

591

1915/1915

2506/2506

710/60R42

716

1830/1830

2546/2546

600/65R28

591

1915/1915

2506/2506

710/70R38

716

1830/1830

2546/2546

Tyre dimensions according to STRO norms.

With tyres

600/65R28, 710/70R38

Total mass with full fuel tank andwithout ballast weights (kg)

7300

Front axle mass (kg)

2920 (40%)

Rear axle mass (kg)

4380 (60%)

The data is valid for tractors with standard track widths and regardless of tyre limitations.

Maximum front axle loading at maximum driving speed (kg)

5500

Maximum front axle loading at working conditions: offroad and with driving speed 10 km/h (kg) Maximumrearaxleloading(kg)

9000

Total weight (kg)

13 500

8500

: The permissible wheel load can reduce the maximum permissible axle load. : On 50 km/h models and when driving at the maximum speed, the tyre loading is smaller. For information on tyre pressure, see the tyre manufacturer's catalogue.

The tyre markings are explained in the following table, tyre 650/65R42 as an example. See tyre manufacturer's documentation for more details. 650

Tyre section width (inches or millimetres)

65 R

Aspect ratio Construction(R:radial;-:diagonal;B:biasbelted)

42

Nominal rim diameter (inches)

168

Load capacity index per tyre (168 = 5 150 kg)

A8

Speed symbol (A8 = 40 km/h)

1.6

Reference pressure (bar)

TL

Tubeless (TL) or tube type (TT)

Model

Page

T4 HiTech

4

21.5.2015 Tractor information 29.2.2016

1

4

5

2

7

6

3

8

GUID-2D5B402F-0F31-4FB7-B622-997AA9AF497F

1

Cab

Prolineinstrumentpanel A-pillar display Cruise control Single door One-key locking system Light panel High visibility roof (additional) Cab suspension (optional) AutoComfort cab & front air suspension (optional) Implement signal connection ISO 11786 (additional) ISOBUS implement control ISO 11783 (additional)

2

Steering

QuickSteer(additional) TwinTrac reverse drive system (additional) electrical adjustable horizontal position including QuickSteer Auto-Guide (additional) including QuickSteer

3

HVAC

Heater (standard) Air conditioning (additional) manual manual and lower heater automatic including lower heater

4

Frontequipment


Frontvalves(additional) 2 pcs 3 pcs 3 pcs + 2 pcs 6/2 divider

9


Front linkage (additional) 51 kN control from front or rear valves Front quick couplings (additional) 1 or 2 pairs Front PTO (additional) Front loader (additional) 7 Optional: 40 km/h: 9/38 - 29/45 (4wd) 50 km/h: 11/37 - 33/41 (4wd) 40 km/h Ecospeed: 11/37 - 33/41 (4wd) Power take-off • • •

•

8

Brakes

electronic control robotized speed change speed - optional: 540/1000 540/540E/1000 540E/1000/1000E 540E/1000+GSPTO 540E/1000E+GSPTO shaft - optional: 6-spline 35 mm (standard) 6-spline 45 mm (additional) 20 splines 45 mm (additional) 21 splines 35 mm (additional)

hydraulicallyboosted electro-hydraulic parking brake brake cooling emergency brake - electrical Pneumatic trailer brake system (additional) 1-/2-line 2-line Duomatic Italy UK Hydraulic trailer brake system (additional) 1:6 1:11

9

Workinghydraulics

• • •

separateoil load sensing variable displacement pump (optional) 115 l 160 l (→ heat exchanger)

Auxiliary hydraulic valves Rear linkage • • •

•

Ball hitch HD, cat. 3 Lift cylinders - optional: 78 kN / dia. 100 mm 95 kN / dia. 110 mm Hydraulic levelling - optional: from quick couplings with control valve

Towing devices (additional)

Model

Page

T4 HiTech

5

Model

Page

T4 HiTech

6


Model

Automation configuration

Standard control units

CAN ID

CAN3

C A N 2

B14M B15M T4 Hitech

EDT1

M5M AC 26.5

(with armrest)

EC

AUXF

LCD P6

ICL

EEM4F

AUX1F =135 AUX2F =136 AUX3F =137 AUX4F =138

EDT3

TC

IO1

HARM

EC = 0 ICL = 23 LCD = 59 TC = 3 IO1 = 4 HARM = 5

CAN1 GUID-C11B01BC-F2D8-43CB-B4C6-68D1E573BF5A

CAN3

B14M B15M T4 Hitech

EDT1

EC = 0 ICL = 23 LCD = 59 TC = 3 IO1 = 4 ARM = 5

M5M AC 26.51

(with basic controls)

EC EEM4F

ICL

LCD TC P6

ARIO1 M

CAN1 GUID-6649CCD2-13F2-4C51-9A8D-7464C3124B93

EC

ECU, EC (engine control unit)

ICL

Instrument panel

LCD

A-pillar display (P6)

TC

ECU, TC (transmission control unit)

IO1

IO1 ECU,

ARM

ECU, ARM (basic controls)

HARM

ECU,HARM(hydraulicarmrestcontrolunit)

AUX

Auxiliary hydraulic valve

EDT1

Diagnostic connector 1

EDT3


B14M, B15M

NOx sensors

M5M

Actuator, waste gate

AGI-4

ECU, Topdock, Auto-Guide

AGI-4 = 28

AM50

ECU, telemetry AgCommand

AM50 = 74

AUTO HVAC

Control panel, AUTO HVAC

EDT2


IO2

ECU, IO2

ISOAD

ECU,ISOadapter(implementsignal connection ISO11786)


AUTO HVAC = 25 — 49 =IO2 ISOAD = 220

Model

Page

T4 HiTech

7


LCD

C-pillar display (P7)

PVED-CL

Steering valve

SASA

Sensor,steeringangle(SASA),front

SASA=769

SECU

ECU, SECU, steering

SECU 50 =

SUS1

ECU, SUS1, AutoComfort

SUS1 47 =

TECU

ECU,ISOBUS,TECU(ISO11783)

TECU=221

TWINTRAC

Steeringunit,rear(witharmrest)

LCD 60 = PVED-CL 19 =

TWINTRAC=772


Model

Page

T4 HiTech

8

Technical details of the tractor are printed on the identification sticker. The sticker is located inside the cover of the cab electric center.

GUID-7D21F76B-4025-4798-9F92-8A5FB0FD9C3D

VIN CODE

Tractor serial number

CHASSISNUMBER

Serialnumberusedbytheproduction

TRANSM.NUMBER

Transmissionserialnumber

AC CODE

Automation configuration code

TRANSM.KEY

Transmissionconfigurationanditsindexnumber

PTOKEY

PTOconfigurationanditsindexnumber

TURBINECLUTCH

Turbineclutchfittedornot

FRONT AXLE

Front axle serial number

AXLE MODEL GEAR PUMP TYREINDEX

Front axle model Gear pump output Tyreindexofthefactoryfittedtyres

If the sticker is lost or damaged, a replacement sticker is available as a spare part.


J

1

H

2

F

3

C

4

D

5

A

6

D

7

45

8

Model

Page

T4 HiTech

9

GUID-F7B38F22-CD74-4B89-9DAA-B585B13DA4D4

1. 2. 3. 4. 5. 6. 7. 8.

Model series Gear pump Final drive / Maximum speed / Pinion shaft / 4WD Creeper gear / Ground speed PTO gear PTO gear Turbine clutch / Sigma Rear linkage lifting cylinder Transmission key index number

I

T144, T154, T174, T194, T214, T234

E

25+19 cm3

F

32+19 cm3

L

750

40

9/38 1)

29/45

M

750

50

11/37 1)

33/41

1)

Crown wheel Ø 330 mm

B

Yes

No

C

Yes

Yes

1)

ID letter is also the first letter of the PTO KEY.


A

540 / 1000

F

1000 540E / / 540

G

1000E 1000 / /540

H

GSPTO 1000 / 540E /

I

GSPTO 1000E 540E //

J 1)

GSPTO 1000 / /540

ID letter is also the second letter of the PTO KEY.

A

No

C

Yes

C

mm

100

Model

Page

T4 HiTech

10

Software

Model

Page

T4 HiTech

1

Software..........................................................................................................1

Software 29.2.2016

Model

Page

T4 HiTech

1

The software of this product is continually developed during the product life cycle. Update the tractor software according to the periodical maintenance schedule. These regular updates of the software ensure that the tractor has all the latest software functionalities. Refer to the tractor software release documents for the latest software information. The content in this manual corresponds to the software version in use at the time of the release of this manual.

Repair

Model

Page

T4 HiTech

1

Repair safety...................................................................................................1 Handling heavy components...........................................................................2 Cleaning components..................................................................................... 3 Assembling components.................................................................................4 Applying sealants.......................................................................................4 Assembling rotating piston rings................................................................4 Assembling shims...................................................................................... 4 Assembling gaskets................................................................................... 4 Assembling lip type rubber seals............................................................... 5 Assembling cables and wires.................................................................... 5 Assembling locking devices....................................................................... 5 Connecting and disconnecting WEO connectors...................................... 6 Starting the engine after major maintenance.................................................. 7 Safety precautions for the electrical system................................................... 8 Electrostatic discharge (ESD)....................................................................8 Handling ESD sensitive components.........................................................9 The AGCO EDT service tool.........................................................................10 Tightening torques........................................................................................ 11

Repair 21.5.2015

Always bear safety in mind when repairing or servicing the tractor.

While supporting the tractor, always check the centre of gravity of the frame part. For example, the wedges must always be fitted between the front axle and engine to prevent axle oscillation when splitting the front frame of the tractor.

Model

Page

T4 HiTech

1

Repair 21.5.2015

Before you start: Unless otherwise specified, all removals should be accomplished using adjustable lifting equipment.

Model

Page

T4 HiTech

2

The angle referred to here is the angle between the supporting members and the object to be removed.

1

2

3

4

GUID-989C2B27-37D8-42C7-AD39-3C5FA001D60E

GUID-EF5B987B-1FF1-4C45-BD5F-83981A0CDD2C

1. 2.

Eyebolt Eyebolt support

3. 4.

Sleeve Load

When necessary the forged eyebolt can be supported with an eyebolt support. The sleeve may or may not be welded to plate.

Repair 21.5.2015

To ensure long life of a machine, it is important to keep dirt and foreign material out of its vital working components. Enclosed compartments, seals and filters have been provided to keep the supply of air, fuel and lubricant clean. These protective devices must not be removed. Cleaning and covering precautions should be taken while disconnecting hydraulics, fuel, lubricating oil or lines and while removing access covers or inspection plates.

Model

Page

T4 HiTech

3

Repair 21.5.2015

Model

Page

T4 HiTech

4

Before you start: : Before fitting new parts, remove rustpreventive compound from all machined surfaces. : Do not fit any components other than those srcinally intended for a particular purpose. The use of other than srcinal AGCO Parts spare parts invalidates the responsibility of AGCO Power Inc. for meeting the emission requirements.

1

Never partially assemble one part then start to assemble another.

Always check the job on completion. GUID-BEC65556-482F-4104-A9DB-229B968AC9A5

1.

Sealant

Encircle all holes in the surface. Make sure that you do not plug oil lines and drillings with the sealant.

: It is recommended to replace rotating piston rings with new ones every time they are removed.

Repair 21.5.2015

Model

Page

T4 HiTech

5

3

4

1

GUID-8B922402-42A0-44CB-9789-5E265DB67C64

2

5

GUID-D49062B8-B070-423B-BC1B-0A5DDF183077

1. 2. 3. 4. 5.

Heel Toe Case Sealing element Ring spring GUID-DF689C51-1BE4-438D-A61B-8729F066510C

Slackening can be prevented by mechanical means such as lock washers, tab washers and cotter pins, or by Loctite type locking agents. • •

: Never fit a lockwasher under a nut or screw to which a specified torque has to be applied. : Always thoroughly degrease components before applying locking agents.

Repair 21.5.2015

1

GUID-A41BC0EF-C07D-4D79-AF92-A88B1CBA138A

1. Assembly stop

• • • • • •

Model

Page

T4 HiTech

6

Repair 21.5.2015

Before you start: Some parts in the exhaust system can be damaged easily by the increased amount of oil and impurities after maintenance work. The system can have excess oil after a major engine overhaul, for example when the pistons are lubricated during the assembly. : Excessive oil can damage the catalysts.

Running the engine burns the extra oil and impurities from the engine.

Model

Page

T4 HiTech

7

Repair 21.5.2015

Model

Page

T4 HiTech

8

Follow the safety precautions for the electrical system. : Make sure that the main power is turned off before disconnecting or reconnecting the battery. : Disconnect the negative lead of the battery first and connect it last.

: Always connect the battery with the correct polarity. : Disconnect the negative battery lead before removing the alternator. : Never open the charging circuit while the engine is running. : Ensure good ventilation when charging. : Do not connect any additional electrical equipment, as this may damage components of the existing electrical system. : All electronic equipment is sensitive to electrostatic discharge (ESD). Take all necessary measures to minimize or eliminate the risk of equipment being damaged by ESD. : The tractor has a negative-earthed alternator that can be damaged easily if incorrect connections are made in the electrical system. For example, connecting the battery with the wrong polarity can burn the alternator or rectifier.

Electrostatic discharge (ESD) is the sudden and momentary electric current that flows between two objects at different electrical potentials. Static charges are generated in objects by friction. Uncontrolled, ESD may damage the sensitive instruments of components such as circuit boards. With help of earthing, the static charge can be discharged in a controlled way. Immediate ESD induced defects lead to an obvious deterioration or complete failure of the component. However, detecting slighter ESD damage can be difficult as electrostatic discharge does not necessarily destroy the entire device. Its functionality may be disrupted partially, or the device may even seem to function properly, but its lifetime reduces dramatically. Sometimes, such damages are not detectable in testing. Hidden defects are usually detected only after the component or device breaks down completely. In complex devices and systems, finding and replacing a single defective component is difficult and expensive. ESD events may occur without visible or audible sparks. Circuit boards can be damaged by static electricity discharges as low as 100V, which is a fraction of the voltage levels that can be detected by human senses. When ESD sensitive elements such as circuit boards are handled, the requirements of the component manufacturer and the ESD standard IEC 61340-5-1 and technical report IEC/TR 61340-5-2 must be complied with.

Repair 21.5.2015

Follow these instructions to protect Electrostatic Discharge (ESD) sensitive components such as circuit boards from damages caused by uncontrolled electrostatic discharges.

Model

Page

T4 HiTech

9

Before you unpack the component or touch the assembly, discharge to earth any electrostatic charges that may have accumulated by touching the earth pin with your bare hand. •

: All electronic equipment is sensitive to electrostatic discharge (ESD). Take all necessary measures to minimize or eliminate the risk of equipment being damaged by ESD.

1

2

3

ATTENTION GUID-DA52793D-126E-44AB-93F6-66915FDFBEF5

OBSERVE PRECAUTIONS

1. 2. 3.

FOR HANDLING ELECTROSTATIC DISCHARGE SENSITIVE DEVICES

GUID-B14EBFA4-7A2B-4D91-AA2C-43253529E03A

ESD wrist strap Three-pin power socket Earth pin

• Wear the earthing wrist strap around your bare wrist and connected to the earth pin until you have completed work with the ESD sensitive component or assembly.

Repair 21.5.2015

Model

Page

T4 HiTech

10

The AGCO EDT service tool (Electronic Diagnostic Tool) is a service terminal (tablet computer) and software used for programming, providing diagnostics for all functions, reading service codes and fault trees, performing calibrations and configurations, changing CAN IDs of control units, the CAN logger and other necessary settings. The AGCO EDT service tool contains also the engine management tools. The AGCO EDT service tool connects to the tractor via CAN BUS interface. Checking for new updates for the AGCO EDT service tool at least once a week is recommended. Connect the AGCO EDT service tool to the Internet to check for updates.

Repair 21.5.2015

Model

Page

T4 HiTech

11

If the repair instructions do not give any specified tightening torque for a screw or nut, use the tightening torques given in the table. If a tightening torque is given without a specific tolerance, the tolerance is ±10%. Tightening torques, metric standard thread (ISO). Dim.

Tightening torques Nm Quality, surface treatment, material and so on 8.8 lubr.

tol. ±

8.8 Zne 1)

tol. ±

8.8 Znk 2)

tol.±

M4

-

-

-

-

-

-

-

-

-

-

M5

6.4

0.6

5.7

0.5

-

-

9

1

11

1

M6

11

1

10

1

12

1.2

15

1.5

18

2

M8

25

2

23

2

30

3

35

4

45

5

M10

50

5

45

5

60

5

70

7

90

10

M12

90

10

80

8

100

10

125

10

151

15

M14

140

15

125

10

160

15

200

20

240

20

M16

220

20

195

20

250

25

300

30

370

40

M18

300

30

270

30

350

35

430

40

510

50

M20

430

40

380

40

480

50

600

60

720

70

M22

570

60

500

50

650

65

800

80

970

M24

740

70

660

70

830

80

M27 M30

100 1 500 1

1) 2)

100 150

Zne = zinc electroplating Znk = hot galvanized

950 300 1

100 130

200 1 600 1

120 160

10.9lubr.

030 1 500 1 040 2

tol.±

100 150 200

12.9lubr.

250 1 800 1 500 2

tol.±

100 120

180 250

Maintenance

Model

Page

T4 HiTech

1

Maintenance................................................................................................... 1 Maintenance schedule....................................................................................2 Service inspection...........................................................................................3 Performing maintenance tasks....................................................................... 4 Cleaning the tractor.........................................................................................5 Cleaning the engine compartment.................................................................. 6 Cleaning front axle suspension bellows..........................................................7 Cleaning polycarbonate windows................................................................... 8 Greasing lubricating points fitted with grease nipples.....................................9

Grease............................................................................................................ 1 Universal Grease - NLGI2 universal grease.............................................. 1 Calsium LF - NLGI2 calsium grease LF.....................................................1 Grease Moly - NLGI2 moly grease............................................................ 1

Periodical maintenance...................................................................................1 Clearing the periodical maintenance view................................................. 1 Periodical maintenance chart..........................................................................2

Maintenance 21.5.2015

Model

Page

T4 HiTech

1

The tractor must be maintained regularly. Correct maintenance at the right time is essential to ensure reliable operation of the tractor. Maintenance costs are small compared to repair costs resulting from lack of maintenance. The most important measures are those you carry out yourself, including lubrication and various checks and adjustments.

18.9.2015 Maintenance 29.2.2016

Model

Page

T4 HiTech

2

You must select running hours-based or annual maintenance schedule for your tractor. With both maintenance schedules the maintenance tasks are carried out according to the periodical maintenance chart. The operator has to carry out the normal daily and weekly service routines according to the periodical maintenance chart.

Running hours-based maintenance schedule must be used for tractors which have more than 600 running hours in a year. The maintenance should be ordered from an authorised Valtra workshop. In that case the maintenance is carried out by Valtra authorised and trained service personnel.

Annual maintenance schedule must be used for tractors which have less than 600 running hours in a year. The maintenance should be ordered from an authorised Valtra workshop. In that case the maintenance is carried out by Valtra authorised and trained service personnel.


Model

Page

T4 HiTech

3

A service inspection is required for all new tractors after 50 running hours. The service inspection is mandatory in order to retain the guarantee. The service is performed by your local dealer. : The tractor is inspected according to the manufacturer's instructions before it is handed over to a customer.

The inspection of the engine contains the following services: • • •

Change of engine oil and filter Change of fuel system prefilter Change of fuel filter

The inspection of the power transmission contains the following services: •

Change of low pressure filter, lubrication filter and pressure filter of the hydraulic system

The inspection of the front axle and steering system contains the following services: • •

Change of oil in differential Change of oil in hubs

The inspection contains the following services as well: • • • •

Lubrication according to maintenance chart Checking the front loader frame bolt tightness (Front loader is optional equipment) Running of transmission automatic calibration Road test of the tractor

During the road test all the functions of the controls and instruments are checked. After the road test, the oil leaks, coolant level and fuel system are checked.


Follow these instructions when maintaining.

Before you start: • • • •

Test drive the tractor and test that all instruments and controls are working properly. Always stop the engine before starting the work. Park the tractor on level ground, especially when doing oil checks. Apply the parking brake to ensure that the tractor cannot move.

Model

Page

T4 HiTech

4

Large amounts of dirt (for example heavily clogged filters) can point to a fault which could cause extensive and costly repairs if not corrected in time.

: If the ground is uneven, block the wheels. •

Wash down the tractor so that the service work can be done easily and quicker.

Observe that if the tractor has extra equipment like towing device, air conditioning, air pressure brakes and so on, the periodical maintenance and checks for them must also be carried out. Follow the instructions concerning general service tasks:

Thoroughly wipe off filler caps and plugs as well as surrounding parts of the tractor before filling up with fuel or oil.

Be sure that the engine and oil have cooled down before checking the oil level. The oil must have run down to the bottom of the oil sump before the operation.

: Make sure that the main power is turned off before disconnecting or reconnecting the battery.

Fuel, lubricating oil and coolant cause irritation to the skin if they are in contact with it for long periods.

After you finish: : After completion of service work, reinstall all shields and covers.


Clean the tractor regularly.

Model

Page

T4 HiTech

5

The paint work may get damaged, if the painted surface is hot.

Before you start:

After you finish: After washing, grease the lubricating points and the joints and lubricate the bearings with oil.

Turn the ignition key to the washing.

(OFF) position before

: Protect the environment by following the environmental regulations. The washing place must have a separator outlet when using detergents.

It is best to wash the new tractor for the first time a week after the start-up. Avoid rubbing the surface of the tractor too hard during the first months. : Do not wax the paint work of the new tractor before the initial washing.

Keep the nozzle of the pressure washer at least 30 cm from the sealing points and paint work. The temperature of the washing water must not be higher than 50°C. : Do not use special nozzles, such as turbo nozzles, when washing. Follow the instructions of the pressure washer manufacturer.

The cab air filter is in the side plate of the roof, usually on the left.

Use lower pressure (6,5 MPa / 65 bar) and point the water diagonally to the above points. Do not point the pressure washer towards the radar sensor (minimum distance 1 m and maximum pressure 6,5 MPa / 65 bar).


Keep the engine surface clean to avoid the risk of fire. : Protect the environment by following the environmental regulations. The washing place must have a separator outlet when using detergents.

: To avoid the risk of fire, do not wash the engine when it is hot.

Keep the nozzle of the pressure washer at least 30 cm from the sealing points and paint work. The temperature of the washing water must not be higher than 50°C. • •

Use lower pressure, 6.5 MPa / 65 bar. Point the water jet diagonally to the engine. :

Do not use special nozzles, such as turbo nozzles, when washing. Follow the instructions of the pressure washer manufacturer.

These components can be damaged easily. Wash the delicate engine parts by hand.

Model

Page

T4 HiTech

6


To ensure correct function of the front axle air suspension, the dirt in the bellows of the suspension and in the housing have to be occasionally removed.

The temperature of the washing water must not be higher than 50°C. : Do not use special nozzles, such as turbo nozzles, when washing. Follow the instructions of the pressure washer manufacturer.

Model

Page

T4 HiTech

7


The polycarbonate windows must be cleaned regularly to keep the windows bright as long as possible.

: Do not use special nozzles, such as turbo nozzles, when washing. Follow the instructions of the pressure washer manufacturer. Do not point the pressure washer towards the side seals or lead-through seals. The possible detergent may reach the glass parts which are not coated.

The coated parts of the windows withstand different detergents well. : Do not use abrasive detergents and do not rub the windows dry.

Ensure that there is enough fluid in the washer reservoir.

Model

Page

T4 HiTech

8


: Preferably lubrication bearing points andcarry jointsout unloaded andwith with the bearings in different positions.

Model

Page

T4 HiTech

9


Model

Page

T4 HiTech

1

Use proper grease for the lubrication points. : Always use proper grease. Each lubrication point requires its own type of grease. : Avoid repeated skin contact with the grease.

: Protect nature and take care of empty packages.

Use Universal Grease for greasing for example wheel bearings, chassis water pumps, caterpillar rollers. Universal Grease: • • •

is a lithium-based universal grease is suitable for greasing all heavy machines stands a temperature range of -25°C...+130°C

The grease is adhesive, protects against corrosion and resists water and varying temperatures.

Use the Calsium LF grease for greasing points exposed to water. Calsium LF is a long-fibre, high-quality, calciumbased universal grease for vehicle use. Calsium LF: • • • •

is suitable for greasing all heavy machines is a long fibre grease is red-coloured stands a temperature range of -25°C...+80°C

The Calsium LF grease is intended to be used for chassis, water pumps, pins and especially for greasing points exposed to water. The grease is adhesive, protects against corrosion and resists water and varying temperatures.

Use Grease Moly for wheel bearings, chassis water pumps, caterpillar rollers et cetera. Grease Moly is a highquality, lithium-based universal grease for vehicle use. Grease Moly: • • •

is a lithium-based universal grease is suitable for greasing all heavy machines stands a temperature range of -25°C...+130°C

The grease is adhesive, protects against corrosion and resists water and varying temperatures. Molybdenum sulphide as an additive (1-3%) improves the greasing in places exposed to shock loads.


Model

Page

T4 HiTech

1

1

20 20

5

25

30 40

5

0

30

50 0

GUID-56496CFD-9F29-4A47-9BBC-E980432028AF

1. Periodical maintenance view

The periodical maintenance view shows when you must perform the tractor service. : When the periodical maintenance view is shown on the display, the service work has to be carried out before the view is cleared. : Clean the tractor before maintenance. The periodical maintenance view has been cleared and will illuminate again when the next service interval has been reached.

Before you start: When the periodical maintenance has been carried out, the periodical maintenance view can be cleared. 1

20

600

20

5

25

30 40

5

0

30

50 0

1.2 17:52

3 2

GUID-FFFE2E4B-4BDB-40A0-B597-26A3F92D34F3

1. Periodical maintenance view 2. Control panel for A-pillar display and Proline 3. Ignition

Model

Page

T4 HiTech

2

18.9.2015 Maintenance 29.2.2016

You must follow the service intervals in the periodical maintenance chart. : When carrying out service you must follow the service intervals, that is, you must also perform all previously required actions mentioned in the periodical maintenance chart. For example, when doing 2400 hours service you must also do the service required at 1200 hours, 600 hours, weekly and daily. : When using Biodiesel fuel there might be exceptions in the periodical maintenance. : The service intervals shown apply for normal operating conditions but in more severe conditions servicing should be carried out more frequently.

• • • • •

The column 10 h shows the tasks that must be carried out daily or every 10 hours. The column 50 h shows the tasks that must be carried out weekly or every 50 hours. The column 600 h shows the tasks that must be carried out every 600 hours. The column 1200 h shows the tasks that must be carried out every 1200 hours. The column 2400 h shows the tasks that must be carried out every 2400 hours.

• • •

The column 10 h shows the tasks that must be carried out daily or every 10 hours. The column 50 h shows the tasks that must be carried out weekly or every 50 hours. The column 600 h shows the tasks that must be carried out yearly.

•

The column 2400 h shows the tasks that must be carried out every other year. Check engine the level. oil

●

Check coolant the level. Checkandcleantheradiatorfinsandenginecovergrilles.

Grease rear the linkage.

●

●

●

●

● ●

●

●

●

Checktheoillevelinthetransmissionandhydraulicsystem. Check and oil for fuel leaks.

● ●

●

● ●

●

● ●

●

●

●

●

● ●

●

● ●

●

●

Check and grease the pick-up hitch.

●

●

●

●

Check and grease the front linkage.

●

●

●

●

Check the front power take-off.

●

Grease the brake mechanism.

● ●

Grease the front axle mounting bearings.

● ●

●

● ●

●

●

●

●

Check the belts' tension.

●

●

●

●

Check tyre the pressure.

●

●

●

●

Check the emergency brake. Check the windscreen washer fluid level. Checktheairpressuresystemantifreezefluidlevel. Check,cleanandgreasethebatteryterminals.

●

● ●

● ●

●

● ●

●

●

●

●

●

● ●

Change the engine oil and filter.

● 1)

●

Changethecabventilationairfilter.

● 2)

●

Change the recirculation air filter. Checkthefrontloaderframebolttightness. Table continued on next page

●

● ● 3)

● ● ●

●

●

Model

Page

T4 HiTech

3

18.9.2015 Maintenance 29.2.2016

Check the wheel nut tightness.

●

●

●

Check the brake pedal free travel.

●

●

●

Check the parking brake.

●

●

Changetheoilfiltersofthetransmissionandhydraulicsystem. Check the engine breathing system.

Checkthefrontpowertake-offcouplings.

Checktheairpressuresystemautomaticwaterdraining. Filltheairpressuresystemantifreezecontainer.

●

●

●

●

●

●

●

●

●

●

●

●

●

Greasetherubbersurfacesofthetrailerquickcouplings. Checktheintegrityoftheairpressuresystem.

●

●

Checktheoillevelinthefrontaxledifferentialandhubs. Changetheoilinthehubsofthefrontaxleswithbrakes. Changethefrontpowertake-offoilandwashtheoilfilter.

●

●

● ●

●

●

●

●

●

●

●

●

●

Updatethesoftwareandcalibratethetractor.

● 4)

Adjust the engine valves.

● 5)

Changetheoilinthetransmissionandhydraulicsystem.

● ●

● ●

●

●

(●) 6)

Change the engine air filters. Change the selective catalytic reduction system breather and supply module

●

●

Changetheoilinthefrontaxledifferentialandhubs. Changethefuelfilterandprefilter.

●

●

(●) 6)

● 7) 8)

●

● 9)

●

● 10)

●

main filter. Check the front wheel toe-in.

●

●

Changethetransmissionandhydraulicbreather. Clean the suction strainer.

● ●

Check the power shuttle operation. Bleed the brake system.

● ●

●

● ●

Bleed the front axle brake system.

● ● 11)

Check the cooling system. Changethecapofthecoolantexpansiontank.

●

Checktheenginevibrationdamper. Check the cab mounting. Maintain the air conditioning. 1)

2)

● ● ●

: In extremely dusty conditions or when using first generation Biodiesel fuel with dilution over 7%, change the oil and filters every 250 hours. With second generation Biodiesel fuel the service interval is normal (600 hours). : In extremely dusty conditions the cab ventilation air filter must be cleaned frequently.

3)

: The front loader frame bolt tightness must be checked every 50 hours if the front loader is used continuously with heavy loads.

4)

: The software must be updated and the tractor calibrated after 600 operating hours. After the first update and calibration, do them at 1200 hours and after this every 1200 hours.

5)

: The engine valves must be adjusted after 600 operating hours. After the first adjustment, adjust the valves at 2400 hours and after this every 2400 hours.

6) 7)

: Perform at 600 hours only if you are following the annual maintenance schedule. : When using first generation Biodiesel fuel with dilution over 7%, change the fuel filter and prefilter every 500 hours. With second generation Biodiesel fuel the service interval is 1000 hours.

8)

: In extremely dusty or cold conditions, change the fuel filter and prefilter every 600 hours.

9)

: In extremely dusty conditions the engine air filters must be changed more frequently.

Model

Page

T4 HiTech

4

18.9.2015 Maintenance 29.2.2016

10)

: In extremely dusty conditions the selective catalytic reduction system breather must be changed more frequently.

11)

: Clean the cooling system and change the coolant regularly. • •

Change the red coolant (ASTM D6210 Type I-FF (OAT-technology)) every 5 years. Change the blue coolant (ASTM D3306) every 2 years.

Engine

01 Engine; fuel and exhaust system Fuel system

Exhaust system

Cooling system

Electronic engine management

Engine

Model

Page

T4 HiTech

1

Engine.............................................................................................................1 Engine designation.................................................................................... 2 Engine lubrication system..........................................................................2 Engine output standards.................................................................................4 Cylinder block................................................................................................. 5 Cylinder liners................................................................................................. 6 Cylinder head..................................................................................................7 Valves and rockers......................................................................................... 8 Tappets and push rods................................................................................... 9 Camshaft.......................................................................................................10 Oversize camshaft bushings.........................................................................11 Crankshaft.....................................................................................................12 Flywheel........................................................................................................13 Timing gears................................................................................................. 14 Connecting rod..............................................................................................15 Piston, rings and pin..................................................................................... 16 Lubrication oil system................................................................................... 17 Oil pump........................................................................................................18 Thermostat....................................................................................................19 Turbocharger................................................................................................ 20 Tightening torques........................................................................................ 21 Engine construction...................................................................................... 23 Cylinder block.......................................................................................... 23 Flywheel housing..................................................................................... 23 Valve mechanism.................................................................................... 23 Cylinder head...........................................................................................23 Crank mechanism....................................................................................23 Timing gears............................................................................................ 24 Lubrication system...................................................................................25 Oil pressure regulating valve................................................................... 26 Oil cooler..................................................................................................27 Closed crankcase ventilation................................................................... 29 Inlet and exhaust system......................................................................... 30 Turbocharger........................................................................................... 31 Throttle valve........................................................................................... 31 Air cleaner................................................................................................32 Viscose-type vibration damper................................................................ 32

Cylinder block tools.........................................................................................1 Timing and flywheel housing tools..........................................................3 Cylindergear head and valve mechanism tools..................................................... 4 Crank mechanism tools.................................................................................. 6

Cylinder block................................................................................................. 1 Measuring the cylinder liner wear.............................................................. 1 Removing the cylinder liner....................................................................... 1 Checking the cylinder block....................................................................... 1 Changing the camshaft bushing................................................................ 2 Fitting the plug at camshaft rear end......................................................... 2 Fitting the plug at camshaft rear end (oversize bushings)......................... 3 Fitting the cylinder liner..............................................................................3

Engine

Model

Page

T4 HiTech

2

Flywheel housing............................................................................................ 6 Fitting the flywheel housing....................................................................... 6 Changing the crankshaft rear oil seal........................................................ 6 Cylinder head..................................................................................................7 Removing the cylinder head...................................................................... 7 Removing the valves................................................................................. 7 Checking the cylinder head....................................................................... 7 Changing the valve guides........................................................................ 8 Machining the valve seat........................................................................... 9 Changing the valve seat rings................................................................... 9 Grinding the valves.................................................................................. 10 Fitting the valves......................................................................................10 Fitting the cylinder head...........................................................................10 Installing the cylinder head connection part.............................................11 Valve mechanism..........................................................................................12 Reconditioning the valve mechanism...................................................... 12 Changing the camshaft and camshaft gear............................................. 13 Adjusting the valves.................................................................................13 Checking the valve clearance..................................................................14 Crankshaft.....................................................................................................15 Removing the crankshaft......................................................................... 15 Checking the crankshaft.......................................................................... 15 Changing the crankshaft gears................................................................16 Installing the crankshaft........................................................................... 16 Checking the crankshaft hub piece..........................................................17 Connecting rods and pistons........................................................................ 18 Removing pistons together with connecting rods.................................... 18 Changing connecting rod piston pin bushing...........................................18 Changing connecting rod big-end bearing............................................... 18 Connecting rod measures........................................................................19 Changing piston rings.............................................................................. 20 Checkingpistons..................................................................................... 20 Fitting the piston pin.................................................................................21 Fitting pistons together with connecting rods...........................................21 Flywheel........................................................................................................23 Changing the flywheel starter ring gear................................................... 23 Removing the flywheel.............................................................................23 Fitting the flywheel................................................................................... 23 Timing gear assembly...................................................................................25 Removing the timing gear casing............................................................ 25 Fitting the timing gear casing...................................................................25 Lubrication system........................................................................................28 Checking the oil pressure regulating valve.............................................. 28 Removing the lubrication oil pump...........................................................28 Disassembling the lubrication oil pump................................................... 28 Assembling the lubrication oil pump........................................................ 28 Fitting the lubrication oil pump................................................................. 29 Changing piston cooling nozzles............................................................. 29 Fitting the oil sump gasket....................................................................... 30 Changing lubrication oil cooler.................................................................30 Fitting the closed crankcase ventilation valve..........................................31 Air control system......................................................................................... 32 Checking inlet and exhaust pipes............................................................ 32 Removing the actuator of the turbocharger............................................. 32 Installing the actuator of the turbocharger............................................... 32 Removing the turbocharger..................................................................... 33 Checking the turbocharger...................................................................... 33 Fitting the turbocharger............................................................................33

Engine 7.4.2015

Designation

66 AWF

Type

Four-strokediesel enginewith common rail direct injection

Turbocharged and intercooling Numberofcylinders

Model

Page

T4 HiTech

1

74 AWF

Yes 6

Transport boost 1)

Yes

Sigma Power 2)

Additional equipment

Standard equipment

Max output, kW/(hp)/rpm (ISO 14396) 129/(175)/1900 Normal

114/(155)/1900

121/(165)/1900

3)

143/(195)/1900

158/(215)/1900

173/(235)/1900

140/(190)/1900 Boost

125/(170)/1900

132/(180)/1900

4)

154/(210)/1900

169/(230)/1900

184/(250)/1900

Max torque, Nm/rpm (ISO 14396) Normal

640/1500

680/1500

740/1500 5)

800/1500

870/1500

930/1500

Boost

680/1500

740/1500

780/1500 6)

870/1500

910/1500

1000/1500

Max no load speed, rpm

2260

Low idling speed, rpm Normal Parkingbrakeison

850 650

1) 2)

3) 4) 5) 6)

Higher transport boost in speed ranges C and D.power transferred through the power take-off is large enough. Sigma Power area, thepower largestarea output/torque area when the

The Sigma Power indicator light 129/(175)/1700 with EcoPower 140/(190)/1700 with EcoPower 850/1100 with EcoPower 900/1100 with EcoPower

Engine type

is lit on the instrument panel.

66

74

Weight 1) (kg)

515

Displacement (litres) Cylinder bore (mm) Stroke (mm) Fuel feed Injectionadvance Directionofrotationfromtheenginefront 1)

525

6.6 108

7.4 108

120

134

Direct injection Automaticallyadjusted Clockwise

Approximate dry weight without flywheel, electrics, CCV and SCR

Direct injection Automaticallyadjusted Clockwise

Engine 7.4.2015

Model

Page

T4 HiTech

2

66 AWF 1

2

3

GUID-EC6A774B-895F-4D3A-AB25-4E48B9293E09

1. Engine control technology F = Tier 4 Final 2. Turbocharged engine W = wastegate turbo 3. Basic type 66 = cylinder displacement (dl) A = after-treatment system

Type Oilpressureatidlingspeed(min)

Gearpump,straineronthesuctionsideandreplaceablefilteronthe pressure side 150kPa(1.5bar)

Oilpressureatnormalworkingspeed

250-500kPa(2.5-5bar)

Type

Disposable type filter element

Valtragrade

ValtraEngineFSValtra / EngineCR-4

SAE grade

• •

10W-40: -25°C...+40°C 15W-40: -20°C...+40°C

API grade

CJ-4

ACEA grade

E9

When changing with filter

19

Viscosity grade should be selected depending on the temperature outside.

Engine 7.4.2015

°C +40

+30

+20

+10

0

-10

-20

-30

0 -3 W 5 E A S

0 -4 W 5 E A S

-40 GUID-FE55727E-2BCD-4347-8B62-354AC8F3DBC5

0 3 W 0 1 E A S

0 4 W 0 1 E A S

0 4 W 5 1 E A S

0 2 W 0 2 E A S

0 4 W 0 2 E A S

3 0 E A S

Model

Page

T4 HiTech

3

Engine 7.4.2015

Model

Page

T4 HiTech

4

ISO 14396 97/68/EC (Valtra 2003→)

2

1 GUID-F918AE93-5CFA-487A-AAF5-5D65BF254373

1. External coolant supply 2. Gross power standard in kW (without a fan) Method of testing: •• •

testing testing temperature pressure 10025°C kPa no engine ancillaries fitted •

•

if water pump drive requires a fan belt, alternator or other ancillaries, these are present but not under load coolant supplied externally

97/68/EC This is an emission standard to which the power measurement according to the standard ISO 14396 has been added. This is why the power measurement is similar to the above mentioned standard.

Engine 7.4.2015

Guide pin holes

Model

Page

T4 HiTech

5

13.250-13.320 mm

Main bearing housing diameter

96.000-96.025 mm

Cylinderlinerupperendlocationdiameter

124.514-124.554mm

Cylinderlinerlowerendlocationdiameter Insidediameterofcamshaftbushingno.1(fitted)

123.000-123.040mm 50.040-50.060mm

Insidediameterofcamshaftbushings,others(fitted)

50.010-50.070mm

Bearingbushingborediameterinblock(bearingbushingno.1) Cylinder block height

55.620-55.650mm 428.170-428.430 mm

Engine 7.4.2015

Protrusionofcylinderlinerabovecylinderblocktopface Max.permissibleheightdifferencebetweenliners (under samehead) Cylinderlinerflangeheight,standard Cylinderlinerflangeheight,1stoversize

Model

Page

T4 HiTech

6

0.030–0.080mm 0.02mm 9.03–9.05mm 9.08–9.10mm

Cylinderlinerflangeheight,2ndoversize

9.13–9.15mm

Cylinderlinerflangeheight,3rdoversize

9.23–9.25mm

Cylinderlinerflangeouterdiameter

131.700–131.800mm

Cylinderlinerguideouterdiameteratupperendofliner

124.475–124.500mm

Cylinderlinerguideouterdiameteratlowerendofliner

122.961–122.986mm

Liner bore

108.010–108.32 mm

Engine 7.4.2015

Model

Page

T4 HiTech

7

Cylinder head height

109.900-110.000 mm

Cylinderheadheightafterrepairgrinding(minimum)

109.500mm

Length of cylinder head bolts

148 (max. 150 mm)

Cylinderstudslength(overalllength) Valve guide inside diameter

186+1mm(max.188.5mm) 8.000-8.015 mm

Valve guide outside diameter Valveguideborediameterincylinderhead Valveguidepositiontopabovecylinderheadsurface

16.028-16.039 mm 16.000-16.018mm 13mm

Depth of inlet valvehead facebelow cylinder head surface

0.65-0.85 mm (max. 2.20 mm)

Depth of exhaust valve head face below cylinder head surface Inlet valve seat angle Exhaust valve seat angle Inlet valve seat width Exhaust valve seat width Exhaustvalveseatringdiameter

0.45-0.65 mm (max. 2.20 mm) 35°+20' 45°+20' 2.2 mm 2.0 mm 36.060-36.122mm

Exhaustvalveseatringsrecessdiameter

36.000-36.025mm

Exhaustvalveseatringdiameter

36.260-36.322mm

Exhaustvalveseatringrecessdiameter Inletvalveseatringdiameter

36.200-36.225mm 41.070–41.132mm

Inletvalveseatringrecessdiameter

41.000–41.025mm

Inletvalveseatringdiameter

41.270–41.332mm

Inletvalveseatringrecessdiameter

41.200–41.225mm

Engine 7.4.2015

Model

Page

T4 HiTech

8

With a valve clearance of 1.0 mm: inlet -valve opens inlet -valve closes

B.T.D.C 2° ± 2° 18° 2° A.B.D.C ±

exhaust valve opens

36° 2° B.B.D.C ±

exhaust valve closes

2° 2° A.T.D.C ±

Inlet valve clearance, hot and cold

0.35 mm

Exhaustvalveclearance,hotandcold Inlet valve face angle

0.35mm 35°-20'

Exhaust valve face angle

45°-20'

Inlet valve head outside diameter

39 mm

Exhaust valve head outside diameter

35mm

Max.inletvalvemovementwithavalveclearanceof0.35mm:

9.5mm

Max.exhaust valvemovementwith avalveclearanceof 0.35mm: Inlet valve stem diameter

9.0mm 7.960-7.975 mm

Exhaust valve stem diameter

7.925-7.940 mm

Inlet valve stem clearance

0.025-0.055 mm

Reject limit -

mm 0.30

Exhaust valve stem clearance Reject limit -

0.060-0.090 mm mm 0.35

Depthof inlet valveheadfacebelowcylinder headsurface

0.65-0.85 mm (max.2.20 mm)

Depth of exhaust valve head face below cylinder head surface Valve spring free length Spring pressurewhenspringcompressedtoa length of 41.0mm

0.45-0.65 mm (max. 2.20 mm) 75.1 mm 300 ±10N

Spring pressurewhenspringcompressedtoa length of 31.0mm

420 ±15N

Rocker arm shaft diameter

24.970-24.990 mm

Rocker arm bore diameter Rocker arm spring free length Springpressurewhenspringcompressedtoalengthof66mm

25.000-25.021 mm 88 mm 75-95N

Engine 7.4.2015

Tappet outside diameter Tappetborediameterincylinderblock Max.permissiblepushroddeflection(whenfree) Push rod overall length

Model

Page

T4 HiTech

9

29.939–29.960 mm 30.000–30.043mm 0.4mm 245–246.3 mm

Engine 7.4.2015

Camshaftbearingjournalno.1diameter

Model

Page

T4 HiTech

10

49.875-49.900mm

Camshaftbearingjournalnos2-4diameter

49.865-49.890mm

Camshaftbearingjournalno.5diameter

49.885-49.910mm

Camshaftclearanceinbearingbushno.1 Camshaftclearanceinbearingbushnos.2-4 Camshaftclearanceinbearingbushnos.5 Camshaft end play Inletvalvecamheight(distancebetweenbackofcamandtipofcam) Exhaust valvecamheight(distancebetween back of cam andtipof cam) Inlet valve cam lift Exhaust valve cam lift

0.110-0.195mm 0.100-0.185mm 0.080-0.165mm 0.350-0.80 mm 43.180-43.680mm 41.700-42.200 mm 6.180 mm 7.700 mm

Cam width

19.700-20.300 mm

Camshaftmaxpermissibledeflection(totalindicatorreading)

0.030mm

Engine 7.4.2015

Model

Page

T4 HiTech

11

If the camshaft bushing location (front bearing) is damaged, a bushing with outer diameter of 0.4 mm oversize can be fitted. Bushings are available also for camshaft bearings that do not normally have bushings. The installing places are the same as with the standard bushings. Observe the position of the oil holes. Bushings do not require reaming after fitting. 1

23

45

6

GUID-F5D507A5-4048-42ED-8DD7-5DDBC5EDF753

1. 2. 3. 4. 5. 6.

Bushing location Bushing location Bushing location Bushing location Bushing location Tractor front

Numbering begins from the front end of the engine.

1.

55.62–55.65 mm

2.

55.42–55.45 mm

3.

55.22–55.25 mm

4.

55.42–55.45 mm

5.

55.64–55.67 mm

Engine 7.4.2015

Model

Page

T4 HiTech

12

Crankpin diameter: standard -

67.981-68.000 mm

1st undersize 0.25 mm

67.731-67.750 mm

2nd -undersize 0.50 mm

67.481-67.500 mm

3rd -undersize 1.00 mm

66.981-67.000 mm

4th undersize 1.50 mm

66.481-66.500 mm

Crankpin length Diameter of the main bearing journal:

40.000-40.160 mm

standard -

89.985-90.020 mm

1st undersize 0.25 mm

89.735-89.770 mm


89.485-89.520 mm

3rd -undersize 1.00 mm

88.985-89.020 mm


88.485-88.520 mm

Diameterofthemainbearinghousing(incylinderblock)

96.000-96.025mm

Thickness of the main bearing shell: standard 1st undersize 0.25 mm

2.955-2.965 mm 3.080-3.090 mm


3.205-3.215 mm

3rd undersize 1.00 mm

3.455-3.465 mm


3.705-3.715 mm

Main bearing clearance

0.050-0.127 mm

Length of the thrust bearing journal (journal nearest to flywheel): standard (2standardthrustplates)

45.000-45.080mm

-1stoversize(onestandardandone0.1mmoverthickthrustplate)

45.100-45.180mm

-2ndoversize(onestandardandone0.2mmoverthick thrustplate)

45.200-45.280mm

-3rdoversize(one0.1mmandone0.2mmoverthickthrustplate)

45.300-45.380mm

-4thoversize(two0.2mmoverthickthrustplates)

45.400-45.480mm

Other crankshaft journals cannot be ground longer. Crankshaft end float

0.100-0.380 mm

Maxpermissibleovalityandotherdeformityofcrankpinsorjournals

0.03mm

Crankshaft unbalance Number teeth of on trigger wheel

1.0 Ncm max. 60-2

Engine 7.4.2015

Model

Page

T4 HiTech

13

Interferencefitbetweenringgearandflywheel Beforefittingtheringgear,heatuptoatemperatureof Flywheel unbalance Max. permissible axial wobble of flywheel clutch face, measured at inner edge of clutch face on diameter 200

0.425–0.600mm 150–200°C Ncm max. 1 0.06:⌀200

Engine 7.4.2015

Tooth backlash Max permissible side wobble of gears

Model

Page

T4 HiTech

14

0.05–0.25 mm 0.05 mm

Timing marks On crankshaft gear

dots 2tooth on

Onidlergearagainstcrankshaftgearmark

1dotontooth

Onidlergearagainstcamshaftgearmark Onidlergearagainsthighpressurepumpmark

1dotontooth 2dotsonnotch

On high pressure pump gear

dot 1on notch

camshaft On gear

notch dot on1

: The timing marks on the gears are in alignment when the first cylinder piston is at its top dead centre (TDC) between compression and power strokes.

Engine 7.4.2015

Model

Page

T4 HiTech

15

Big-end bearing shell thickness: standard 1st undersize st 0.25 mm

1.835-1.842 mm 1.960-1.967 mm

2nd undersize 0.50 mm

2.085-2.092 mm

3rd undersize 1.00 mm

2.335-2.342 mm


2.585-2.592 mm

Big-end bearing clearance Endfloat(sideclearance)atbig-endoncrankshaft Piston pin bushing location perpendicular to longitudinal axis of connecting rod to be within

0.046-0.098 mm 0.200-0.410mm 0.15:100

Piston pin bushing location and big-end bearing location to be parallel to within

0.05:100

Max. permissibleweight differencebetween connecting rods in thesameengine

20 g

Weight marking

letter lower aatend

Insidediameter of piston pin bush (with bush pressedinto connecting rod)

40.025-40.040 mm

Outsidediameterofpistonpinbush(standard)

44.080-44.120mm

Outsidediameterofpistonpinbush(oversize)

44.580-44.620mm

Interferencefit:connectingrodsmall-endbushing-connectingrod: Connecting rod small-end bore Connectingrodsmall-endbore(oversizebushing) Connecting rod big-end bore

0.057-0.120mm 44.000-44.025 mm 44.500-44.525mm 71.730-71.749 mm

Engine 7.4.2015

Pistondiameter(17mmfromloweredge)

Model

Page

T4 HiTech

16

107.883-107.897mm

Pistondiameter(19mmfromloweredge)

107.893-107.907mm

Pin bore piston in

40.003-40.009 mm

Piston pin diameter

39.991-40.000 mm

Width of ring grooves: groove 1st-

wedge-shaped ring

groove 2ndgroove 3rd-

2.560-2.580 mm 3.040-3.060 mm

Side clearance of piston rings in their grooves: ring 1st-

wedge-shaped ring

ring 2nd -

0.03-0.062 mm

ring 3rd Reject limit -

0.05-0.082 mm mm 0.15

Piston ring height (in direction of cylinder): ring 1st-

wedge-shaped ring

ring 2nd-

2.470-2.490 mm

ring 3rd -

2.970-2.990 mm

Piston ring gap (with piston fitted in cylinder): ring 1st -

0.30-0.45 mm

ring 2nd -

0.80-1.00 mm

ring 3rd -

0.35-0.60 mm

Reject - limit 1st and 3rd ring Reject -limit 2nd ring Maximumpermissibleweightdifferencebetweenpistons insameengine

1.0 mm mm 1.5 25g

Engine 7.4.2015

Model

Page

T4 HiTech

17

Oil pressure at normal running temperature: idling at speed -(min) running at speed -

bar 1.5 2.5–5.0 bar

Regulation valve of the oil pressure: Freelength of the spring of theoil pressurevalve (identification = yellow dot)

49.3–50.8 mm

Assembly length / load of the spring of the oil pressure valve Bypassvalveoftheoilfilteropensatapressuredifferenceof

28.5 mm / 127 N 2±0.5bar

Engine 7.4.2015

Model

Page

T4 HiTech

18

Backlash between gears when crankshaft lies firmly against the lower side of the main bearings: crankshaft gear-lubricatingoilpumpgear between the pump gears

0.05-0.25mm 0.16-0.26 mm

Diameterofdriveshaftatbearingsforbodyandcover

17.966-17.984mm

Diameterofdriveshaftbearingholeonbodyandcover

18.000-18.018mm

Innerdiameterofbearingforgearwheelwhichrotatesonfixedshaft

18.000-18.018mm

Diameter of fixed shaft at gear wheel Fixed shaft in pump body, diameter

17.966-17.984 mm 20.035-20.048 mm

Protrusionoffixedshaftendbelowpumpbodyface

0.5mm

Cover gasket thickness Gear wheels outer diameter Housing diameter Gears thickness Gears play end Housing depth

0.06-0.08 mm 55.824-55.870 mm 56.000-56.120 mm 32.000-32.027 mm 0.03-0.11 mm 32.000-32.043 mm

Engine 7.4.2015

Model

Page

T4 HiTech

19

ø67 83°C mm /

83°±2°C

95°C

8.0 mm

ø54 79°C mm /

79°±2°C

94°C

7.5 mm

Engine 7.4.2015

Model

Page

T4 HiTech

20

Maximum axial clearance

0.1 mm

Maximum radial clearance

0.5 mm

Engine 7.4.2015

Cylinder head bolts

80 Nm + 90° + 90°

Cylinderheadconnectionpartscrews

50Nm

Main bearing screws

200 Nm

Connectingrodscrews

40Nm→80Nm+90°

Crankshaft nut

1000 Nm

Crankshaft pulley screws 1)

30 Nm

Crankshaft pulley screws 2)

80 Nm

Flywheel screws

150 Nm

Idler gear screws

180 Nm

Camshaft gear nut

200 Nm

Rockerarmshaftbracketscrewandnuts

45Nm

Valvecoverandframescrews

25Nm

Piston cooling valve

30 Nm

Oil pump retaining screws

60 Nm

Oil sump drain plug (M18)

80 Nm

Oilcoolerconnectingpiece

60Nm

Coolant pump pulley screw •

M10

• M12 Coolant pump pulley nut Belt tightener screw

•

50

• 120 Nm

80

48 Nm

Exhaust manifold screws

50 Nm

Injector retainer screw

40 Nm

Injector wire nuts (M4)

1.5 Nm

High-pressurepumpgearnut

80Nm

Fuel filter elements

40 Nm

Pre-filter water detector

Nm 6

Compressorgearnut(LHthread)

160Nm

ECU screws

Nm 10

ScrewsoftheECUrubberdamper

30Nm

Injector wire nuts

1.5 Nm

BoltsoftheSCRsupplymodule

19Nm±20%Nm

ScrewsoftheSCRdosingmodule

8Nm±2Nm

Pressurecontrolvalve 1) 2)

80Nm±4Nm-90°+85Nm±5Nm

With models T144H or T154H With models T174EH, T194H, T214H or T234H

M8 M10

Nm

35

Nm

80

M12

Nm 140

M14

Nm 200


Model

Page

T4 HiTech

21

Engine 7.4.2015

M16

Nm 300

M20

Nm 700

M22

Nm 700

Model

Page

T4 HiTech

22

When a special torque value is not available, the different threads have these general torque values. A washer is necessary with aluminum parts.

M8 M10

Nm

25

Nm 50

Nm

35

Nm 75

Engine 7.4.2015

Model

Page

T4 HiTech

23

The cylinder block is the main body of the engine, to which other engine parts are attached. Wet and replaceable cylinder liners are supported at the middle, which reduces vibrations and directs coolant circulation mainly to the upper part of the liners. The seal between the lower part of the cylinder liner and the cylinder block is achieved by three O-rings. The Orings are fitted in grooves in the liner. The upper part is sealed by the cylinder head gasket. The camshaft is in the cylinder block. There are separate bearing sleeves in all camshaft bearing locations and the drilling for the camshaft rear end is covered with a plug. There are spaces on both sides of the rear main bearing for guide bearing shims (the crankshaft thrust bearings).

The flywheel housing is fitted at the rear end of the cylinder block. The seal for the crankshaft rear end is placed in a bore in the housing. The starter motor fixing point is fitted 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 cylinder block must be level with the flywheel housing. When fitting the flywheel housing, its position is determined by tension pins.

The valve mechanism is operated by the camshaft which is located in the cylinder block. The drive is transferred with the is help of tappets push feed rods.lubrication The camshaft gearthrough wheel is fittedoilways with a nut andcylinder guided block. with a key. Each bearing lubricated by and the force system drilled in the

A six cylinder engine has two cylinder heads. Every cylinder has four valves and in the middle of the valves there is a place for the injector. The injector is located vertically in the centre of the cylinder and in the middle of the combustion chamber. This ensures accurate and homogenous mixing of fuel and air and leads to clean and low emission combustion with good efficiency. Each cylinder has its own inlet and exhaust ports located on either side of the head. Every inlet valve has its own inlet port but there is only one exhaust port for every two of the cylinder’s exhaust valves. There are no water holes on the inlet side of the cylinder head. This eliminates the possibility of water entering the inlet air. Cylinder head bolts are high tensile bolts, which are tightened up to yield limit using the angle tightening method. Due to the large stretch, the tightening forces are kept constant during the whole lifetime and retightening is unnecessary. The injector and its side feeding pipe locations are machined directly into the cylinder head. The port for the side feeding pipe is located between the inlet ports. The inlet and exhaust valve guides are identical and can be interchanged. Inlet and exhaust valves are fitted with separate valve seat rings.

The crankshaft is forged from chrome alloy special steel and is induction hardened at the bearing and sealing surfaces. This makes it possible to grind bearings four times without a new heat treatment. Gear wheels are located at the front end of the crankshaft. They are a press fit, and drive the idler wheel and oil pump. The belt pulley/vibration damper is fastened to the crankshaft with a cone joint. An oil deflector ring is fitted between the hub and gear wheel.

Engine 7.4.2015

Model

Page

T4 HiTech

24

The crankshaft is supported on the cylinder block by main bearings, which are placed on both sides of each cylinder. There is therefore one main bearing more than there are cylinders. The crankshaft thrust washers are placed in both sides of the rearmost main bearing. A flywheel, on which there is a press-fit starter ring gear, is fitted at the rear end of the crankshaft. The forged connecting rod has an I-cross-section. The bearing location at the bottom end of the connecting rod is fracture-split, and the bearing cup is secured by two special elongated screws. The upper part has a wedge-shaped bearing location, in which the piston pin bearing bushing is fitted with a press fit. The piston is made of a eutectic aluminium alloy. In the upper face of the piston there is a combustion chamber. The shape of the chamber is intended to maximise the mixture of air and fuel. The upper ring location is formed in a cast iron ring, which is cast in the piston. In addition, the piston is graphite-coated to ensure correct running-in. The piston has three rings. The upper molybdenum-coated ring has a wedge-shaped cross-section. The middle ring is tapered and it fits into its groove. The taper takes up the clearance. The oil control ring is spring-loaded and it has a two-stage, chromed scraping edge.

4

1

2

3

GUID-215213A2-811C-4D4F-AB96-57AED69DB392

1. 2. 3. 4.

Camshaft gear Idler gear Crankshaft gear High-pressure pump gear

The timing gear drives the camshaft, high-pressure pump and oil pump. The timing gear train consists of hardened, helically cut gear wheels. The gears are encased by the timing gear casing, which is fitted to the front of the engine. The idler gear is supported with a ball bearing on the shaft on the front face of the cylinder block.

Engine 7.4.2015

1

Model

Page

T4 HiTech

25

2 3

4 5

6 7

8

GUID-59FFA815-F838-44DB-AA8F-796778B5E50B

1. 2. 3. 4. 5. 6. 7. 8.

Turbocharger Oil cooler Oil filter Piston cooling nozzle Main oil gallery Oil pressure sensor (B6M) Oil pump Oil pressure regulating valve

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. Engine is equipped with closed crankcase ventilation (CCV) system. There is Super Impactor type CCV system with boost air. CCV system is maintenance-free.

Engine 7.4.2015

Model

Page

T4 HiTech

26

GUID-6E4D9696-DA4C-4E2D-9C5C-70ABE565493B

The 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.

Engine 7.4.2015

1

2

3

4

5

6

7

8

GUID-0DB63D17-E889-4B93-9248-8873A1DFB41A

Model

Page

T4 HiTech

27

Engine 7.4.2015

1. 2. 3. 4. 5. 6. 7. 8.

Model

Page

T4 HiTech

28

Cooling water out Cooling water in By-pass valve for the cooler Oil Drain plug for the cooling water Oil filter By-pass valve Connection piece (60 Nm, Loctite 243)

The oil cooler is placed between the filter and the cylinder block. The oil circulating in the cooler is cooled with engine the engine coolant.

Engine 7.4.2015

2

1

3

Model

Page

T4 HiTech

29

4

5

6

7 3

8

9

11

GUID-C0115DE8-FFCA-47DE-8F58-5B81D2D2F0E0

1. 2. 3. 4. 5.

Hose (from cover to engine air intake) Hose (from valve mechanism to cover) Hose, boost air (from the inlet manifold to cover) Assembling (hoses straight when mounting) Return hose (from engine lower part to crankcase)

10

Engine 7.4.2015

6. 7. 8. 9. 10. 11.

Model

Page

T4 HiTech

30

Ventilation hole Jet nozzle and jet pump Variable impact separator Pressure regulator Connector (with an anti-suction check valve) Pre-separator

In the closed crankcase ventilation system, oil is separated from the breathing air with the help of boost pressure. The pressure regulator located on the filter side equalizes pressure in the crankcase so that it corresponds to the outside pressure. is done by the from amount of incoming breathing air. The separated oil is returned to the crankcase andThis so protects theregulating environment contamination.

1 2

4

5

3

6

GUID-3D9D9B3A-42D6-48C4-AE63-1F9F1BD22B9F

1. 2. 3. 4. 5. 6.

Air filter Turbocharger Throttle valve Air-to-air intercooler Engine radiator Intake manifold

The filter system for the engine inlet air consists of a cyclone type pre-cleaner and a paper filter which acts as the main filter. The incoming air is made to rotate in the cyclone pre-cleaner. This causes most of the impurities to settle out and collect in the cyclone pre-cleaner dust collector. The filter is made of corrugated paper and has one or two replaceable filter elements. The corrugated paper is surrounded by a metal support.

Engine 7.4.2015

Model

Page

T4 HiTech

31

The impurities in the air collect at the larger filter element, which can be cleaned when necessary. The inner safety filter prevents impurities from entering the engine if the main filter element breaks or is fitted incorrectly. A mechanical or electrical service indicator can be mounted on the filter housing or on the inlet pipe to show when the filter cartridge is clogged. The inlet system also includes the hoses between the air cleaner and the turbocharger and between the turbocharger and the intake manifold. The exhaust manifold is attached to the cylinder head with high-tensile bolts without a separate gasket. Retightening of the manifold bolts is unnecessary.

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. 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). An engine fitted with a turbocharger is more sensitive to disturbances and impurities in the inlet and exhaust systems than a naturally aspirated engine. The whole inlet and exhaust system should therefore be checked thoroughly for any repair need.

GUID-B4F45648-7274-42A6-A918-3A0EC5FDFCB4

Intake throttle valve is used to manage temperatures in the exhaust gas aftertreatment system. The throttle valve controls the Air/Fuel ratio to speed up engine warming, increase exhaust temperatures at low loads and decrease exhaust temperatures at high loads. The throttle valve is controlled by electronic control unit ECU with the PWM current. The throttle valve has an integrated actuator.

Engine 7.4.2015

Model

Page

T4 HiTech

32

The air cleaner consists of the main air filter and safety air filter. Keeping the air cleaner in good condition is essential for engine performance and service life. A defective air cleaner allows impurities to pass through, which in time damages the turbocharger and the engine. A blocked air cleaner reduces the engine output and also causes oil leakage through the sealing ring on the turbocharger shaft.

2 1 3

4

GUID-97040EA5-E111-4F45-B5EB-2DA7ABCE2153

1. 2. 3. 4.

Housing Damper mass Liquid cavity Bushing

The engine has a viscose-type vibration damper. The damper has a housing filled with stiff silicone oil in which the damping substance has very small tolerances. : Even a small dent makes the vibration damper inoperative. It must not be loosened or removed by force. If there is a dent on the outer surface, the damper must not be reinstalled on the engine. : If you make permanent installation markings on the vibration damper, an electric pen must be used. Stamping the marking will break the damper. Temporary markings can be made with a marker pen.

Engine 7.4.2015

905173100

Model

Page

T4 HiTech

1

Puller for cylinder liner

GUID-0C894D48-1394-4932-A0E3-4B7E3C4E3294

910165600

Millingcutterforcylinderlinerseat

904587600

Sparecuttingbladeformillingcutter

GUID-1D614A6E-D530-4C0A-8622-F314986152A1

905246620

Drift for 40 mm cup plug

Engine 7.4.2015

GUID-BDAB18DA-574E-4DD6-A8F2-4E535D7E15FC

905246650


GUID-8FFFEA23-688A-40EA-ADCA-B7B9263926C9

902587400

Driftforfittingcamshaftcupplug

GUID-2079BE24-0DBF-49A4-8ED9-BC7E2AE235B3

910166300

Press tool for cylinder liner

GUID-8E0B2D37-BC67-49DA-9AE1-3A62A6E11AFB

902579200

GUID-B51D0F9B-6709-41A9-99CC-D12BAB595D1C

Holder for dial gauge

Model

Page

T4 HiTech

2

Engine 7.4.2015

905246400

Model

Page

T4 HiTech

3

Centringtoolforflywheelhousing

GUID-A0F87E9E-AF67-4810-83E3-D642670CCB40

905246300

Driftforfittingrearcrankshaftseal

GUID-7994C55A-9D27-4E33-88F7-0241365924E0

910394600

Driftforfittingfrontcrankshaftseal

GUID-CCC0125B-4C3A-4C52-9AAB-E880CC72018C

902598800

Driftfortensionpinsintiminggearhousing

GUID-AE041BFC-6DCA-4EAA-8639-88CB5EEF9C8F

902598700

GUID-38637C93-6CC2-40D8-B20B-277FBDD7BDCE

Driftfortensionpinsintiminggearhousing

Engine 7.4.2015

920179670

Fittingtoolforvalvestemgasket

GUID-4300A48D-E949-4E06-99C6-00152F8AFB1A

837062635

Millingcutterkitforvalve seat

GUID-03720E51-0475-4535-B6C9-2C35F766A275

912085400

Milling tool for injector seat

GUID-C02E2B7C-29C7-45EB-81E8-8559A1C4082F

921085300

Page

T4 HiTech

4

Tighteningtoolforinjectorwiringconnector

GUID-2433F087-6CB0-4701-AE25-B10274E413C8

920185580

Model

Drift for removing valve guide

Engine 7.4.2015

GUID-FED49636-632F-4848-B9E2-7F812D910389

912085000

Drift for fitting valve guide

GUID-1537DBB6-5730-4977-A232-B235127BAA02

905246660


GUID-38B69548-5077-46F4-82B6-3CE6CFCBF517

910394800

GUID-6486088A-9D8C-49EA-A2EF-29FD03DB8963


Model

Page

T4 HiTech

5

Engine 7.4.2015

905248800

Puller for crankshaft gears

GUID-0AF17DE6-351B-4206-90A0-A78FA0F98C4D

902455800

Spanner for crankshaft nut

GUID-C6FA2C41-8EAF-4F77-8A57-C78DE528E18A

920182390

Puller for crankshaft hub

GUID-10B7F976-3B58-412E-9325-815948B51430

920185840

Piston fitting tool

GUID-835161E4-2BA9-46E9-905C-FB72DCBC94F5

905246900

GUID-28D4D1C0-32CC-4952-802E-06C91EF0EF09

Piston ring pliers

Model

Page

T4 HiTech

6

Engine 7.4.2015

910394900

GUID-F87A609E-6B08-4E5D-B81C-7B2322999B03

Model

Page

T4 HiTech

7

Driftforfittingoildeflectorring,crankshaftfrontend

Engine 7.4.2015

Model

Page

T4 HiTech

1

Use the special tool 905173100.

1

GUID-B9C4E6E7-1487-4971-A44E-3164B5188994

1.

Special tool 905173100

GUID-9F2D8E78-E245-41E3-91A8-2B8DC0279CDC

After you finish: : If it is necessary to machine the upper face of the cylinder block, the pistons must be shortened by the same dimension. Observe the valve disc spaces on the pistons' upper face.

Engine 7.4.2015

Model

Page

T4 HiTech

2

All camshaft bearing points are provided with a separate bearing bushing.

30°

Observe the different outer diameters when removing.

Observe the different outer diameters. Note the position of the oil hole. It is unnecessary to ream the bushing because it has a correct inner diameter when it is fitted in place. 1

2 3

45

6

GUID-32A45FEF-FBEF-484B-A556-812420A944D8

The camshaft front end bushing is equipped with the oil groove on the outside. You do not need to ream the camshaft bushing. It has a correct inner diameter when it is fitted in place.

GUID-F5D507A5-4048-42ED-8DD7-5DDBC5EDF753

1. 2. 3. 4. 5. 6.

Bushing location Bushing location Bushing location Bushing location Bushing location Tractor front

Use the special tool 902587400. : Do not drive in the plug too far because it will affect the camshaft end float.

1.

55.62–55.65 mm

2.

55.42–55.45 mm

3.

55.22–55.25 mm

4.

55.42–55.45 mm

5.

55.64–55.67 mm

1

GUID-8F4AF5CC-B814-4333-A0B2-4B06659B738C

1.

Max 1.0 mm

Engine 7.4.2015

Model

Page

T4 HiTech

3

Use the special tool 910165600. 1

1

2 3

GUID-2CC477DE-CECF-4659-83C6-6A7EA2C7B02C

1. 2. 3.

Plate Plug O-ring

GUID-27F894D9-79CC-41D3-96F9-B0A32249A760

1.

Without O-rings, the liner should rotate easily in its recess.

• •


Lapping is not suitable for adjusting the cylinder liner height. • •

Engine 7.4.2015

Model

Page

T4 HiTech

4

Use the two special tools 910166300. Height

1

Marking grooves pcs

9.03+0.02 -(std.) 9.08+0.02 1 9.13+0.02 2 9.23+0.02 3

Cylinder liners with oversize flanges (higher flanges) are marked with grooves on the outer circumference as follows:

2

3 GUID-F3B17161-6742-4882-8870-EF2F1AFFEFE1

GUID-52CA260D-D103-41C8-9998-C88EED20BBDE

1. 2. 3.

Cylinder liner height Special tool 902579200 Special tool 910166300

• • •

1st oversize, 0.05 mm = 1 marking groove 2nd oversize, 0.10 mm = 2 marking grooves 3rd oversize, 0.20 mm = 3 marking grooves

: Recess depth is adjusted with a cylinder liner recess cutter 910165600. Use a dial gauge and the special tool 902579200. • • The height of the liner above the cylinder block face should be 0.03...0.08 mm. The height difference between cylinder liners under the same cylinder head must not exceed 0.02 mm. An intermediate cylinder liner must not lie lower than an outer one.

Cylinder liners with warped flanges should be discarded.

Engine 7.4.2015

• : Stretch the O-rings as little as possible when fitting them. Maximum permissible stretch is 6%.

Model

Page

T4 HiTech

5

It should be easy to press them fully home. In some cases pressing down the cylinder liners is difficult. • • •

Check the O-rings. Make sure that the O-rings are well lubricated. Check the contact surface in the cylinder block.

1 GUID-F69D43A0-A2E2-4446-AF03-96DA692D1252

1.

Green O-ring

• : Do not use engine oil for lubricating the cylinder liner O-rings.

GUID-77D8432E-76A1-452F-A2C4-430D47BAE200

Engine 7.4.2015

Model

Page

T4 HiTech

6

: Do not damage the crankshaft.

: If the crankshaft is worn at the sealing location, a 2-mm spacer ring can be fitted in front of the crankshaft rear oil seal.

1

2

GUID-B782336C-DD95-423F-BCB5-14EAC7B5AABA

1. 2.

1

GUID-571B3B71-336B-4823-8B03-B3B45BCC2FE6

1.

Spacer ring 2mm

••

Silicone sealant

The sealing lip must not be damaged. • Use the special tool 905246300.



The tightening torque for the inner ring socket head bolts is 80 Nm and for the outer ring hexagonal bolts 150 Nm.

Engine 7.4.2015

Model

Page

T4 HiTech

7

: To avoid the risk of fire, do not wash the engine when it is hot.

GUID-E01140F6-1F62-4310-86F0-A607DD5D55F1

: It is possible to remove the cylinder head even though these parts are attached to the head. : Replace the valve cover seals.

An uneven or warped surface should be surface ground. The height of the cylinder head, after grinding, should not be less than 109.50 mm. The valve disc depth from the cylinder head surface should be 0.60 mm for the exhaust valves and 0.80 mm for the inlet valves.

Engine 7.4.2015

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8

Use the special tool 912085400. 1

GUID-D7B3B1C2-6651-4418-95D5-BD1A9F91D3DA

1.


GUID-A4B0FBEE-BDAD-4387-BD36-229937B48E88

• • The clearance must not be greater than 0.30 mm for the inlet valves and 0.35 mm for the exhaust valves. •

The guides are the same for the inlet and exhaust valves.

GUID-55EF89F3-0B50-49A3-8B16-3ED195636FA6


1

GUID-0C8CB671-9950-46FA-A044-EC54DC3BF22F

1.


Engine 7.4.2015

Use the special tool 912085000. Using the special tool ensures the correct fitting height 13 mm over the spring face.

Model

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T4 HiTech

9

All valves are fitted with separate valve seat rings.

Before you start: Change the valve seat ring if the sealing surface is damaged so badly that it cannot be repaired with machining.

2

1

Exhaust valve:

GUID-6F852C03-BDE8-4F29-87D2-C6F49C40C0E9

1. 2.

1

Special tool 912085000 13 mm

2

GUID-3711DA33-1A8C-4529-8A4E-B2884827BB98

1. 2.

9.8 mm 36.000...36.025 mm

Inlet valve:

1 1

2

GUID-3306DB44-F81B-4645-81EB-9FA41A662E6C

1. 2.

9.8 mm 41.000...41.025 mm

GUID-AE565152-7043-458E-B506-374141411A63

1.


Use the special tool 837062635. If the width of the seat exceeds 2.0 mm in the exhaust and 2.2 mm in the intake, reduce it primarily at the outer edge. The valve seat angle is 45°+20' for the exhaust valve and 35°+20' for the inlet valve.

: Where necessary, standard size seats can be replaced by inserts with a larger outer diameter.

Engine 7.4.2015

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10

Before you start: To ensure a proper seal around the valves, there is a difference in the sealing surface angles. There is therefore a very narrow sealing surface which seals effectively even after prolonged running.

1

2 2

1

GUID-54B04A6C-050C-4200-A63B-B18F63DA4830

3

1. 2.

GUID-B885CD7C-E4B6-4A1B-B7FE-42EBEE05D221

1

2

Inlet

35º-20'

35º+20'

0.8±0.05 (max. 2.20)

Exhaust

45º-20'

45º+20'

0.6±0.05 (max. 2.20)

Max 150 mm Max 150 mm

(mm) 3

Adjust angles to 45°-20' for exhaust valves and 35°-20' for inlet valves.

• •

: Ensure that the cylinder heads are parallel. The exhaust manifold can be damaged if the cylinder heads are not parallel. •

Use a valve spring press.

Engine 7.4.2015

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11

Tighten the cylinder head bolts in the correct order. The order does not show on the cylinder heads. The sealing is more efficient this way. 1 1

GUID-5A30F770-029A-41FB-8DA2-6F47D75093E0

1.

Tractor front

• • • GUID-2F7629F6-1465-4E75-A9AE-3710E8ABEDF0

1.

gaskets

The valve clearance is 0.35 mm for both inlet and exhaust valves. The tightening torque is 50 Nm. : After this, the cylinder head does not need retightening.

After you finish: Tighten the exhaust manifold nuts to 50 Nm. Do not overtighten.

1

GUID-C8853525-123C-4799-B58A-9ABFE0EF1AAE

1. Exhaust manifold nut

Engine 7.4.2015

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12

• Observe the correct position of the shaft and the bearing brackets.

Discard worn or damaged tappets. •

The tightening torque is 25 Nm.

Also check the spherical surfaces at the ends. The length of the push rod is 245–246.3 mm.

1 1 GUID-3C665442-2C2F-4FEC-B369-733617AC9E70

• •

GUID-6E655CF0-7831-42F4-9003-8D03C203584C

1.

Fitting position.

1 1 GUID-9EE8951D-12FB-49E0-AB61-C5A6891ACD61

1.

25.000–25.021 mm

• •

2

3

GUID-2B71823C-6C1B-4A8F-B123-3EC9D33A8B93

: Do not grind the rocker arm valve contact surface more than necessary, as the hardened layer is thin.

1. 2. 3.

Mechanism screw End plug Right end clearance

• • Tightening torque is 45 Nm. • Tightening torque is 25 Nm.

Engine 7.4.2015

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13

Ensure that the aligning marks on the gears correspond.

After you finish: Adjust the valves and fit the valve cover. : Replace the valve cover seals.

Before you start: You can adjust the valve clearance on a hot or cold engine. The valve clearance is 0.35 mm for both inlet and exhaust valves. The clearance is adjusted when the respective piston is at top dead centre (TDC) in the compression stroke. Adjust the valves for the different cylinders in the same sequence as the order of injection.

•

1

GUID-38EAD0BD-878B-41EA-8F4C-5E3EC30894C4

GUID-3F848324-E2A9-412F-96A7-32E4B4CDE72C

: Do not connect the push rods too tightly as this might cause them to bend or snap.

Tighten the nut to 200 Nm.

1. Valve clearance 0.35 mm

Engine 7.4.2015

1 2

3

4

GUID-672C061A-5D54-40A8-822C-98A0BA8DE2FC

1. 2. 3. 4.

Exhaust valves Injector Inlet valves Feeler gauge

Injectionorder

1-5-3-6-2-4

Valves rock in cyl. no.

6-2-4-1-5-3

Model

Page

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14

Engine 7.4.2015

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15

GUID-D5F2C82F-D4DC-4BFC-84BA-3F15A6BB70F1

This way the indicator shows the actual bearing clearance. Measure the internal diameter at several points in case the worn bearing housing is not round.

Grinding is needed if the bearing clearance exceeds 0.18 mm for main bearings or 0.14 mm for connecting rod big-end bearings with new bearing shells. : When grinding, make sure that the journal edges remain round.

GUID-2D645AD9-1B32-4FFF-9F3F-A55E76554AF5

Out-of-round, taper or other wear must not exceed 0.03 mm.

Engine 7.4.2015

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16


1

GUID-5B912772-013F-4BA7-B522-D1924E5EB600

1.



Make sure that you can install the clamping claws of the bearing shell to their notches and that the shells that you install in the cylinder block have a hole align with the oil port. 1 2 1

GUID-8ED80604-2242-4C39-AAEB-22CADA00C97C

1. Special tool 910394700 Observe the position of the key and ensure that the aligning marks on the front gear are visible.

GUID-11A476AB-3BAA-4EFE-886F-E70B596E8F36

1. 2.

Bearing with oil holes and groove Bearing with no holes

Engine 7.4.2015

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17

1

1

7

GUID-4A75686F-744A-407C-B863-8B312AD5DF54

1. 6

GUID-F1F7C98F-FCA2-473E-9277-0914430346B1

1.

Tightening torque 200 Nm

•

End float

The correct end float is 0.10...0.38 mm. If the end float is too large, install oversize thrust bearings. : Measure the end float also after you have connected the engine to the transmission. : Bearing shells should never be reamed or machined in any other way, nor should the sides of the bearing caps be filed.

The rear thrust bearings have locating slats. •

GUID-373752E5-0A86-4295-B20E-009D3DF6EB3C

: Pay special attention to the wearing of the hub piece sealing surface.

Engine 7.4.2015

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18

Ensure that the oil hole in the bush coincides with the respective hole in the connecting rod. Cut and ream the piston pin bushing to obtain the correct shape and diameter.

If the turning edge is clearly marked, smooth it down carefully with a scraper.

Place the bearing shells in order if they are to be reused.

1

2

Use the shaft of a hammer or similar wooden tool.

: If the piston pin does not move under thumb pressure, the piston should be heated to 100°C.

Use a cylinder gauge. GUID-F444485A-455C-427E-AC60-C34AADE17ED5

1. 2.

Ø5 mm Ø40.025 - 40.040 mm

: Fit the connecting rod with a 0.5 mm oversize bushing if needed.

GUID-134EAE52-D43E-4218-9C06-02E0BC3E22E1

If the piston pin bushing is worn, it should be driven out using a suitable drift.

Use a cylinder gauge which has been zeroed to the diameter of the respective bearing journal. If the clearance exceeds 0.14 mm with new bearing shells, the big-end journals require grinding. : Ensure that the radiuses at the end of the bearing journals are not altered when grinding.

Engine 7.4.2015

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19

The connecting rods are divided into weight classes with intervals of 20 g. The weight class (a letter) is stamped on the side face of the connecting rod. All the connecting rods in one engine should be of the same weight class.

1

GUID-761FF8E3-A975-4BF4-83C4-6AB2BFA2A0E1

1. Weight class letter

Weight class letter

Weight

F

1935-1954 g

V

1955-1974 g

X

1975-1994 g

Y

1995-2014 g

W

2015-2034 g

Z

2035-2054 g

G

2055-2074 g

Engine 7.4.2015

Before you start: : Pistons and piston rings must be handled with care to prevent any scratches to the rings or any damage to the piston ring sliding surface.

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20

Push one piston ring at a time into the cylinder bore. The piston ring gap must not exceed 1 mm on the first and third piston rings and 1.5 mm on the second piston ring.

Use the special tool 905246900. Do not open the rings more than is necessary. If the rings are to be used again ensure that they are fitted in the same groove.

GUID-0A7EE74A-E662-4AC9-AD28-E00F8C37413F

Use the special tool 905246900. Ensure that the rings are fitted in the correct groove and that "TOP", or the manufacturer's designation, faces upwards. GUID-D94173E6-BD8E-4ECF-AA47-A0F9D6158769

DS

: The piston ring clearance must be smaller than 0.15 mm. • •

GUID-46A79858-24B0-49AD-AA7E-37E92D7BB488

Pay special attention to any cracks on the edge of the combustion chamber and on the upper edge of the piston pin hole.

Engine 7.4.2015

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21

: If the piston pin does not move under thumb pressure, the piston should be heated to 100°C. The arrow on the piston points towards the front end of the engine. 1 2

1 GUID-2EC41D05-59CB-4AB4-AB2E-8F20CED5C5F0

1. 2.

Measuring diameter Measuring height

17.0mm

107.883–107.897mm

19.0mm

107.893–107.907mm

2

GUID-403B6093-BD12-4ECC-91BC-C097260DC0BA

1. 2.

Engine direction arrow Weight class letter

Ensure that the circlips are pressed correctly into the grooves. The circlip ends must point upwards.

Note the position of the bearing shells.

Engine 7.4.2015

• • •


Fit the bearing cap so that the notches for the guide lugs are in the same side. • • •

Model

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22

Engine 7.4.2015

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23

Before you start:

Before you start:

If the ring gear is worn, replace it with a new one.

Split the tractor between the central frame and engine.

The suitable fitting temperature is 150°C–200°C.

The inner diameter chamfering must be turned against the flywheel and the teeth chamfering against the starter motor. 1

2

1

GUID-00BBCF5C-8C75-4A77-BD63-021A9DBC6519

1.

GUID-3F7F8F85-5F12-4F0D-B4CC-56316EEAAE8E

1. 2.

Inner diameter chamfering Teeth chamfering

Flywheel retaining screw

Engine 7.4.2015

Use two suitable studs as guide pins. Screw the studs into the flywheel fixing screw holes.

GUID-6A86DF80-753F-4205-95FE-47C3D5BC2A52

1

GUID-2BBA7A33-AE77-44B3-81A5-0A8F59B8362F

1.

Plug

Push a large screwdriver through the hole on the left side of the flywheel housing.


Model

Page

T4 HiTech

24

Engine 7.4.2015

Before you start:

Model

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T4 HiTech

25

Use the special tool 920182390. Take off the special tool, open the nut and remove the hub.

The oil sump must be removed before removing the casing.

If the engine has an air compressor or air conditioner, it must be removed.

1

Use the special tool 902455800. GUID-A5525716-23FB-4BE4-9394-1DCBBF5CDA2E

1.


: If the timing gear casing does not need changing, the high-pressure pump can remain in place. In this case, disconnect all leads and pipes from the pump.

1 GUID-C777AECC-A709-447D-8E9C-16F996494575

1.

Special tool 902455800 Ensure that none of the sealing surfaces are damaged.

Notice the oil deflector ring behind the sealing ring.

The position of the timing gear casing and cover is determined by two tension pins. The front cover is

Engine 7.4.2015

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26

positioned by a tension pin and idler gear shaft. Centring should therefore not be undertaken in connection with fitting. However, the tooth backlash between the different gears should be checked. Casing and covers that are delivered as spare parts have holes for the tension pins already machined.

Use Loctite 574. GUID-0185B689-2C89-472F-937A-8B3756A3972D


The tooth backlash should be 0.05–0.25 mm.

Use Loctite 574. : If the oil deflector ring was removed from the front of the crankshaft, fit it before installing the front cover.

Tighten the nut to 200 Nm.

Notice the sealing rings under the idler gear screws.

1

GUID-1E685CF4-CB06-400C-A60E-A357C6FF9413

1.

Front cover screw holes

Rotate the idler gear shaft so that the front cover screw holes are vertically aligned.


Use 12.9 screws with locking compound. The tightening torque is 45 Nm.

Observe the timing mark position.

1 GUID-089FF06F-A1E7-46BF-BCD6-6CC16932F5AB

1.


Use the special tool 910394600. If the hub piece is worn out at the sealing surface, a 3-mm spacer ring can be fitted under the crankshaft rear oil seal.

Engine 7.4.2015

Do not use oil, it may run into the conical surfaces.

±100

The tightening torque is 1000

Nm.

Model

Page

T4 HiTech

27

Engine 7.4.2015

Model

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28

Check the oil pressure regulating valve if the pressure of the engine lubricating oil is insufficient or varies. 1

Hit the end of the shaft with a soft hammer.

Change damaged parts and all seals. GUID-CB366F3F-D16D-43F2-983F-C441D64F9F90

1. Locking fluid on the valve seat The size of the bearing bushings must be 18.000-18.018 mm after fitting. The bearing points are provided with separate bearing bushings.

Change any damaged parts. Scrap off any remains of the gasket.

Fit the cover using a new gasket. Partly tighten the screws.

Use locking fluid Loctite 638.

Use the drift.

Ensure that any shims between the lubrication oil pump and the cylinder block is also removed along with the lubrication oil pump.

Tap the side of the cover such that it reaches the position in which the shaft rotates most freely. Tighten the screws and check that the shaft still rotates freely.

Engine 7.4.2015

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29

Apply Loctite 242 onto the nut threads and tighten the nut to 60 Nm. Note the washer under the nut.

The clearance should be 0.05-0.25 mm. The clearance is adjusted with shims between the pump body and the cylinder block. One shim increases or decreases the backlash by about 0.07 mm. 1

GUID-F82338F2-6D99-4B52-972C-E9B946634E1D GUID-D759C989-BA74-43BC-99B0-37F09AB12070

1.

Nut

Use Loctite 242. The clearance should be between 0.03-0.11 mm. This clearance is adjusted by the number of gaskets between the cover and the body. Engines with high output are fitted with piston cooling nozzles. The piston cooling nozzles have a valve with an opening pressure of 2.3±0.25 bar.

1

Before you start: The piston cooling nozzles can be removed only after the oil sump is removed.

GUID-246A1057-BD14-4186-80D1-B120C3875DE2

1.

End float

Engine 7.4.2015

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30

Change the valve if necessary.

1

GUID-A3066E2B-AE21-48F1-B17E-DD4EB2339987 GUID-DC5A9340-A721-4036-AAA1-14304D145F76

1.

Oil sump gasket

The nozzle pipe should be fitted at 90° angle to the centre line of the crank shaft.

Before you start: Drain the engine coolant before removing the lubrication oil cooler.

1

1

GUID-C120EC08-8557-45A5-B0F2-D95D0EFA7069

1.

Nozzle pipe angle 2

Ensure that the nozzle pipe does not touch the pistons or connecting rods when the engine is running.

3

GUID-171D1F71-3EC3-4B36-B497-495C5E569FD2

1. By-pass valve 2. Draining plug 3. Connection piece

The tightening torque is 30 Nm. The oil cooler is positioned between the oil filter and the cylinder block.

Engine 7.4.2015

Use Loctite 243.


The Closed crankcase ventilation (CCV) filter is mounted on the rear end of inlet manifold. It is connected to valve cover, inlet manifold and inlet pipe. The CCV system includes also a return oil pipe nonreturn valve that is mounted on the engine oil pressure regulating valve cover.

GUID-877D52A1-A0C6-4300-8EE0-00976801BA1D

Ensure that there are no unnecessary bends or creases on them. The hose line must be straightforwardly ascending.

Model

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31

Engine 7.4.2015

: Leaks in the inlet or exhaust system drastically reduce the effect of the turbocharger. Due to the pressure, even small leaks in the manifold or the turbine inlet contact flange quickly increase in size. For this reason, all leaks must be dealt with immediately.

1

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32

Tighten the exhaust manifold fixing nuts to a torque of 50 Nm.

Inspect for damages such as cracks, deformation, and corrosion.

2

3

Check that the sealing surfaces are flat. If the fastening flanges are twisted or there are scratches on the sealing surfaces, machine the flanges or renew the exhaust manifold.

1 GUID-ED17E709-0857-4FA5-A773-2651BBA1015E

1. Exhaust gases

Any loose objects or impurities can increase the back pressure for the exhaust gases from the turbine wheel.

2. Lubrication oil 3. Inlet air

: Do not remove the link rod of the actuator. If the intake manifold is dusty inside, there is a leak in either the air cleaner or the inlet pipes. Fix the leak.

Use a straight ruler. If the surface is not flat or has scratches on it, machine or renew the intake manifold. Make sure that the cylinder heads are parallel.

You can install a new, spare-part actuator in all engine types. When you start the engine for the first time with the new actuator, you also calibrate the actuator for that engine type. After the calibration, you can use the actuator only in engines of that same type.

Tighten the intake manifold fixing screws to a torque of 30 Nm. Use the top bleeding plug on the engine.

Engine 7.4.2015

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33

Place the stylus of the dial gauge against the end of the shaft and move the shaft axially.

The vanes must not show any signs of damage, deformation or wear caused by foreign objects. GUID-04965F23-023F-4F61-8CE1-5DAF4AF87308

Oil leaks through the sealing rings on the shaft in the turbine and compressor housing must be checked. : At a low idling speed, there will be a certain amount of oil leakage on the compressor side. However, this should not be a cause of concern unless the oil consumption is too high.

66

0.10 mm

74

0.10 mm

Place the stylus of the dial gauge against the shaft and move the shaft sideways. Ensure that there are no loose carbon or rust particles and other foreign objects in the inlet and exhaust manifolds.

Tighten it using a new gasket.

GUID-49B8C9B7-5EDE-46B8-8F39-1522A325FD5B

66

0.50 mm

74

0.50 mm

Engine 7.4.2015

This is important in order to ensure that the turbocharger is lubricated when the engine starts.

1

GUID-C41F82F4-AC43-4810-8819-85F6056C134F

1.

Bearing housing

Use a new seal. Check that there is no tension in the pipes when tightening.

Check that there are no leaks.

Model

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34

Fuel system

Model

Page

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1

Technical specifications..................................................................................1 Injection system......................................................................................... 1 Injectors..................................................................................................... 1 Fuel system............................................................................................... 1 Tightening torques..................................................................................... 1 Fuel quality and storage requirements............................................................2 Fuel............................................................................................................2 Quality requirements for engine fuel.......................................................... 2 Storing fuel.................................................................................................3 Biodiesel fuel............................................................................................. 4 Fuel system.....................................................................................................5 Fuel filters....................................................................................................... 6 High-pressure pump....................................................................................... 7 Rail..................................................................................................................8 Pressure control valve and pressure sensor...................................................9

Fuel system tools............................................................................................1 Injector tools....................................................................................................2

Measuring the fuel feed pressure................................................................... 1 Bleeding the fuel system.................................................................................2 High-pressure pump....................................................................................... 3 Removing the high-pressure pump............................................................3 Fitting the high-pressure pump.................................................................. 3 Injectors.......................................................................................................... 5 Checking the injectors............................................................................... 5 Injector CRIN3-20........................................................................................... 6 Removing the injector................................................................................ 7 Fitting the injector...................................................................................... 7 Fitting the delivery pipes................................................................................. 9 Rail................................................................................................................10 Removing the rail.....................................................................................10 Changing the pressure control valve....................................................... 10 Changing the pressure sensor.................................................................11 Changing the high-pressure pipes........................................................... 11 Return quantity test.......................................................................................12 Preparing the return quantity test............................................................ 12 Test instructions.......................................................................................13

Fuel system 7.4.2015

Pumptype Pump gear ratio

Model

Page

T4 HiTech

1

CP4-20/2(2cylinders/radialplungers) 2 :3

Injectionsystem Maxinjectionpressure Injection order

DirectinjectionwithCommonRail 2000bar 4-2-6-3 5--1

Type

CRIN3-20

Nozzle

9-hole

Boost current

A 25

current Hold

A 12

Return flow pressure

Fuel Maxcontinuousfuelinlettemperature Fuelsystemprefilter Fuelsystemmainfilter

0.15 - 0bar

ThefuelmustconformtotheEN590:2009standard. 80°C Donaldson10 Donaldson5

Injector retaining screw Injector wire nuts (M4) High-pressure pump gear nut

Nm 40 Nm 1.5 80±5 Nm

High-pressure pump retaining screws High-pressurefuelpipestohigh-pressurepumpandrail Low-pressurefuelpipestohigh-pressurepump elements Filter Prefilter water detector

25±5 Nm 30Nm 30±2Nm Nm40 Nm 6

18.9.2015 Fuel system 29.2.2016

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2

Make sure that the correct fuel is used. The properties of light fuel oil that is only intended for heating do not meet the requirements of modern diesel engines and therefore it cannot be used as fuel. The high-pressure pump of the Common Rail system requires the fuel to have sufficient lubricity, because it does not havewith separate lubrication. oilit to diesel is forbidden, because it causes carbon build-ups, and if oil is mixed even aoilsmall amountAdding of water clogs thefuel filter. : Even a small quantity of AdBlue/DEF in the fuel tank will cause damage to the engine. If you think that there is AdBlue/DEF in the fuel tank, remove the fuel from the fuel tank and clean it carefully before you start the engine.

Additionally, various fuel quality requirements imposed by taxation and seasonal changes have to be taken into consideration.

The fuel must conform to the standard EN 590:2009 or ASTM D 975-10b. Fuel that does not meet the requirements can cause malfunctions in the fuel injection system and aftertreatment system. The malfunctions can cause serious issues in other engine components too and shorten the engine life. Also, the engine will not meet the emission requirements if the fuel is not permitted for the engine. The fuel must meet the sulphur requirement, biodiesel requirement and standard as stated in EN 590 (2009 or newer). Diesel fuels of ultra low sulphur levels (≤15 mg/kg) that fulfill the requirements of EN 590 (2009 or newer) are allowed. Supplementary admixtures or additives are not allowed. Fuels or mixtures which include for example ethanol, gasoline or kerosene are not allowed as they can shorten the engine life and cause severe system failure. Cetane number must be minimum 43. Cetane number above 47 is preferred, especially for temperature below -20° Celsius and elevations of 1500 meters or more above sea level.


Fuel has to be stored in a dry and clean environment.

The storage tanks must be installed in a slanted position, so that water and impurities are collected at the opposite end of the pump suction pipe. The pump suction pipe must not reach the bottom of the tank.

Model

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3

18.9.2015 Fuel system 29.2.2016

Model

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4

The use of first-generation biodiesel which has a biodiesel content lower than 10% fatty acid methyl esters (FAME) / fatty acid monoalkyl esters (FAAE) does not require changes in the engine or its maintenance. Fuel blends with biodiesel content higher than 10% are not allowed. Allowed fuels EN590-Europe ASTM D 975 - North America 15940 TS BTL EU

Maximum allowed first-generation biodiesel content 0-10%fattyacidmethylesters(FAME)/fatty acid monoalkyl esters (FAAE) 14214 EN

Standard for biodiesel blend EN 14214 ASTM D 6751

18.9.2015 Fuel system 29.2.2016

Model

Page

T4 HiTech

5

7

14

15

9 1 6 10

7

13

2 3

12 5

8

4

11

GUID-1DCAE22A-4D52-411A-8138-454BD01F9C1C

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Injector Pressure sensor High-pressure pump (including mechanical fuel feed pump) Fuel feed pressure sensor (vacuum) Fuel cooler Rail Fuel feed pressure sensor Fuel main filter, 5 Pressure control valve Mechanical hand pump Water-in-fuel sensor Fuel prefilter, 10 , and water separator Fuel tank Continuous air ve nting Temperature sensor (outlet side)

The engines are equipped with a common-rail system controlled by electronic control unit (ECU). Fuel is drawn from the tank via the pre-filter, through the main fuel filter to the high-pressure pump. This pressurised fuel is lying in a high-pressure pipe, where it is controlled and injected through electronic injectors controlled by the ECU. The injection is optimised 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 highpressure pump and rail to the fuel tank. The overflow pipe from the filter helps the bleeding of the system. The fuel is diesel fuel according to the norm EN 590:2009, and it must be clean and free from water after storage. The fuel system includes two fuel transfer pressure sensors, one before the feed pump and one before the main filter, as well as a fuel temperature sensor. The pressure sensors are monitored by the engine control unit (EC).


Pre-filter Efficiency Fuelfeedpressure

Model

Page

T4 HiTech

6

Main filter 10 ~1.0barabs.(vacuum)

5 ~5bar(minimum3.5bar,maximum8.5bar)

The fuel pre-filter also includes the water-in-fuel sensor (standard) and a water separator.


1

Model

Page

T4 HiTech

7

3 4 5

10

6 7 2 8

9 11

3 12

1. 2. 3. 4. 5. 6. 7. 8.

Metering unit Camshaft with cone High-pressure pipes from the cylinder head to the rail Feed pump Fuel to the main filter Fuel return to the tank Fuel from tank (through pre-filter) Fuel from the main filter

9. 10. 11. 12.

Plunger Integrated suction valve Roller tappet Cam drive

• • •

Fuel-lubricated two-cylinder radial plunger pump Maximum rail pressure 2000 bar Maximum continuous fuel inlet temperature 80 ºC


2

1 GUID-6CCB3BDB-F66F-4584-9C59-4D823A78AAB2

1. Pressure sensor 2. Pressure control valve (PCV) Forged rail with pressure sensor and pressure control valve. •

Maximum pressure 2 000 bar (PCV)

Model

Page

T4 HiTech

8


Model

Page

T4 HiTech

9

2

1

1. 2.

Rail pressure sensor Pressure control valve

• • •

Measures constantly the pressure in the rail and provides the information to the electronic control unit (ECU) Has 5 V DC supply voltage Tightening torque is 70 Nm.

• • •

Normally operates when the rail pressure has to be dropped fast, for example, from full throttle to idle speed. Lowers the pressure from the rail if the pressure is too high, that is, over 2000 bar. Tightening torque is 85 ± 5 Nm.


ACV0047940

Fuel filter wrench

GUID-4A8C05A3-035A-47E2-BA7E-7216AF3D6FE5

837062744

GUID-AAF821D7-74B0-42E1-A941-67460B5F0934

Return quantity tester

Model

Page

T4 HiTech

1


912085400

Model

Page

T4 HiTech

2

Milling tool for injector seat

GUID-C02E2B7C-29C7-45EB-81E8-8559A1C4082F

920179670

GUID-2433F087-6CB0-4701-AE25-B10274E413C8

Tighteningtoolforinjectorwiringconnector


Before you start:

The thread is M10x1. 1

1.

Feed pressure sensor

The prescribed value is 4.5–5.5 bar. If the pressure is below the prescribed value, this may be caused by the following reasons. • • •

Clogged fuel filters. Suction piping clogged or leaking air. Empty fuel tank or unsuitable fuel.

Model

Page

T4 HiTech

1


After changing the fuel filters or if the engine has ran out of fuel the fuel system has to be bled. 1

2

GUID-647FB64A-BC65-43E4-856B-A428F80A6D02

1. Hand pump 2. Bleeding plug

: Do not use the hand pump when the engine is running. Do not use any tools or excessive force on the hand pump.

Continue the pumping until there are no air bubbles in the fuel stream.

Model

Page

T4 HiTech

2

The fuel system removes automatically the air left in the system.


Model

Page

T4 HiTech

3

Use a mirror. The high pressure pump gear is behind the idler gear

The timingpump markpiston, is usednot forthe timing the highpressure engine.

Pay attention to the guide ring used in the highpressure pump.

1

2

3

Contact your nearest Bosch Diesel agent or AGCO Power Inc. service department.

4

Before you start:

5

6

7

If the gear housing front cover has not been removed, fix the gear to the shaft of the pump. The guide ring of the high-pressure pump has to be fixed to the pump flange before the gear is fixed.

GUID-E486594D-9C4B-4B99-B922-8AA44A3C95DD

1.

Engine idler gear

2. 3. 4. 5. 6. 7.

High-pressure pump gear High-pressure pump Inspector plug View on the mirror Timing mark on the high-pressure pump gear Timing mark made on the idler gear by a marker pen

1

GUID-F4564618-62B3-4482-9885-70750A30E2C1

1.

O-ring


Model

Page

T4 HiTech

4


1

2

1

GUID-638D21C2-B9BC-4019-811C-F3085FA82346

1. 2.

O-ring High-pressure pump guide ring


GUID-C6BC4808-59DB-4A03-92A2-738C81A1C311

1.

High-pressure pump fixing screw

Low-pressurepipes

30Nm

High-pressurepipe

30Nm

1

1

2

GUID-641F933D-C14F-488F-ADF7-C7E6A215DE38

1.

Gear nut

GUID-4B026CD5-B329-40DD-A44E-2793116BBA0F

1. 2.

High-pressure pipe Low-pressure pipe fixing screw


Use the AGCO EDT service tool.

: The nozzle on the injector cannot be changed. Update the injector information in the AGCO EDT service tool.

Model

Page

T4 HiTech

5


Model

Page

T4 HiTech

6


Model

Page

T4 HiTech

7

•

Before you start: • : The injector and the feeding pipe are calibrated as a couple. Do not mix them up.

1 1 2 2

3

3 4 4

5 5

6

6

7 8

7 8

GUID-66E5F05C-6F6B-43E4-B401-09A083B1C7E3

1. 2. 3. 4. 5. 6.

Injector wiring Fastening screw Washer Fastener Feeding pipe’s control balls Feeding pipe

7. Fastening nut 8. Sealing ring

GUID-66E5F05C-6F6B-43E4-B401-09A083B1C7E3

1. 2. 3. 4. 5. 6. 7. 8.

Injector wiring Fastening screw Washer Fastener Feeding pipe’s control balls Feeding pipe Fastening nut Sealing ring


1. 2.

Pre-tighten the fastening screw to 15 Nm Undo the fastening screw

3. 4. 5.

Pre-tighten the fastening nut to 15 Nm Tighten the fastening screw to 40 Nm Tighten the fastening nut to 50 Nm

Model

Page

T4 HiTech

8


Before you start: Check the delivery pipes and replace the damaged pipes. If there are damages by chafing or kinks or if the tapered sealing end is damaged, the pipes must be changed.


Model

Page

T4 HiTech

9


Before you start:

Model

Page

T4 HiTech

10

Use proper degreasing materials for cleaning and compressed air for drying. The cleaning material must not penetrate the electric contacts. 1

GUID-1636FF6A-CC3B-4DB2-8ED1-011594294BC3

1.

Pressure control valve

1.

Loosen the pressure control valve.

2.

Pull out the pressure control valve and simultaneously turn it anti-clockwise.

Models N134, N154 and N174 have the pressure control valve. The pressure control valve is delivered as a spare part. You can change the pressure control valve while the rail is in position.

Before you start:

Radial scratch is not permissible.

Wait until the system finishes the afterrun before you do any repair or service work on the valve. : The pressure control valve must not be reused. : After engine shutdown, the rail pressure stays at 800 bar. In the SCR system afterrun mode, the ECU gives empty injections to the injectors, thus allowing the rail pressure to decrease.

1. 2. 3.

Tighten the pressure control valve to 80 Nm ± 4 Nm. Loosen the pressure control valve by 90°. Tighten the pressure control valve to 85 Nm ± 5 Nm.

After you finish: The electric cable must not be under tension.


1

GUID-062A9596-AA73-42B0-8389-82B774B48433

1.

Pressure sensor

Radial scratch is not permissible.


: Replace the high-pressure pipes every time they are removed.


After you finish:

Test-run the tractor and check the high-pressure pipes for leakages.

Model

Page

T4 HiTech

11


Before you start: 2 1

GUID-13D0834B-F29A-498C-BCA8-6A4CFFDABED5

1. 2.

Return line pipe that connects the injectors The return pipe that needs to be plugged

If not plugged, this pipe will leak fuel during the test.

Model

Page

T4 HiTech

12


Model

Page

T4 HiTech

13

During the test, the injectors fill the measuring cylinders with the return fuel. Engine speed during the test: • •

The test can be conducted at any engine speed. If the engine performance or sound is not normal at certain engine speed area, the test should be conducted at the same engine speed.

• Engine load during the test can be simulated with a brake bench. Engine temperature during the test: • •

The test can be performed on both a cold engine and an engine running in a normal working temperature. If problems occur in a certain temperature, the test should be conducted in the same temperature.

Duration of the test: • •

The test should be run until one of the measuring cylinders is filled with fuel. If the test is conducted with the engine under load, that is, in a brake bench, the testing duration can drop significantly.

Test results: •

• •

In a normal situation, the fill-up speed of each cylinder should be about the same. The overall fill-up speed or the amount of fuel in the cylinders does not indicate the problem. The problem appears if one of the cylinders fills up much faster or slower than the other cylinders. If one of the cylinders fills up faster than the others, the side feed pipe may not be properly tightened. If one of the cylinders fills up slower than the others, it might indicate a faulty injector. 1

2

GUID-327AEBD4-058E-4F7C-8BCB-82DC099BA45C

1. 2.

Side feed pipe not properly tightened Faulty injector

Exhaust system

Model

Page

T4 HiTech

1

Technical specifications..................................................................................1 Selective catalytic reduction system.......................................................... 1 Dosing system........................................................................................... 1 AdBlue/DEF quality and storage requirements...............................................2 AdBlue/DEF............................................................................................... 2 Storing AdBlue/DEF...................................................................................3 SCR system principle......................................................................................4 SCR system overview.....................................................................................6 SCR system components............................................................................... 8 Electrical equipment; SCR system................................................................10

SCR system tools........................................................................................... 1

SCR system....................................................................................................1 Disconnecting the exhaust system............................................................ 1 Aftertreatment system................................................................................2 Changing the selective catalytic reduction system breather and supply module main filter...................................................................................... 3 Removing the supply module.................................................................... 4 Installing the supply module...................................................................... 4 Installing the dosing module...................................................................... 5 Finding solution to the DEF pressure buildup failure................................. 6 Doing the lifting capacity test of the supply module................................... 6 Finding solution to the failure when the SM lifting capacity test is unsatisfactory.............................................................................................7 Seeding the DEF....................................................................................... 7 Finding solution to the failure when the SM lifting capacity test is OK.......8 Doing the dosing rate test..........................................................................8 Finding solution to SPN 4090 FMI 16 NOx emission too high...................9 Examining the quality of DEF.................................................................... 9

Exhaust system 7.4.2015

System type

Forest tank capacity

1

DIN70070/ISO22241-certifiedAdBlue/DEF

45 liters

Approximately 6-8% of fuel consumption 1)

Pre-filters

1)

T4 HiTech

70 liters

DEF consumption

Main filter

Page

Bosch DENOXTRONIC 2.2+

Fluidtype Tank capacity

Model

100 10

DEF consumption may be higher, depending on the application and load profile of the engine.

Minimumoperatingtemperature

-40°C

Maximum DEF temperature

70 °C

MaximumSCRsystemtemperature

80°C


Model

Page

T4 HiTech

2

The recommended additive is a urea-based fluid sold under the brand name AdBlue/DEF. AdBlue/DEF is a colourless fluid containing urea and distilled water. The concentration of urea in AdBlue/DEF is 32.5%. The AdBlue/DEF additive must conform to the standard DIN 70070. AdBlue/DEF is not a hazardous product, but itwith must be handled with care. In the event of spillage of AdBlue/DEF on the vehicle, rinse off with water and wipe paper or a cloth. : Store AdBlue/DEF in temperatures under 30°C. Do not store in direct sunlight. : AdBlue/DEF freezes at -11 °C. Take the necessary storage precautions to keep the product from freezing and to ensure the vehicle can be topped up at all times. : If the AdBlue/DEF additive is modified or replaced by another fluid, which does not comply with standard DIN 70070, there is a risk that it will not provide the intended result, and it may damage the engine.


Before you start: In order to guarantee the stability of AdBlue/DEF (as per DIN 70070 standard), the following storage recommendations should be followed:

: AdBlue/DEF freezes at -11 °C. Take the necessary storage precautions to keep the product from freezing and to ensure the vehicle can be topped up at all times.

If AdBlue/DEF is stored at high temperatures, the solution may crystallise and release an ammonia odour.

Model

Page

T4 HiTech

3


Model

Page

T4 HiTech

4

22 8

11

13 12

14

23

15 17

1

16

5

3

9 20

2 6

10

21

24

19

4

7

18

GUID-AE55E259-0923-4BFB-B034-EEE00E73A16F

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

NOx sensor Temperature sensor Engine coolant lines for cooling of dosing module DOC Pressure line Dosing module Mixer Supply module Actuators Temperature sensor Backflow line Quality sensor Temperature sensor Engine control unit Inlet line Sensors

17. 18. 19. 20. 21. 22. 23. 24.

Engine coolant lines for AdBlue heating SCR catalyst Temperature sensor Engine CAN Diagnostic CAN AdBlue tank Level sensor NOx sensor

The Stage 4 / Tier 4 exhaust line is a significant part of the engine emission control system. The first part of controlling the exhaust gas emissions is accomplished by precise control of the combustion process in the


Model

Page

T4 HiTech

5

cylinders. The second part is conducted with exhaust gas aftertreatment system consisting of catalysts in the exhaust line and Bosch reactant fluid dosing system. The exhaust line includes two catalyst units, reactant fluid dosing module, two NOx sensors and three temperature sensors. The first catalyst unit is an oxidation catalyst (Diesel Oxidation Catalyst), and the second catalyst unit is an NOx reduction catalyst (Selective Catalytic Reduction). The dosing module is needed for injecting reactant fluid into the exhaust gas flow before the SCR catalyst. The mixing of reactant and exhaust gas can be improved by placing mixing elements upstream or downstream of the dosing module location. The NOx sensor and temperature sensor measurement values are used for controlling the reactant dosing amount and as inputs for the system diagnostics functions. The DOC coating contains platinum which catalyses the oxidation of hydrocarbons (HC) and carbon monoxide (CO) to water vapour and carbon dioxide (CO 2). Part of nitrogen oxide (NO) is oxidised into nitrogen dioxide (NO 2) in the DOC, which results in a beneficial effect on the reaction speed of the SCR reactions. The NOx reduction with the SCR catalyst is achieved by injecting reactant fluid into exhaust gas flow before the SCR catalyst. The reactant fluid is a solution of deionised/demineralised water and automotive-grade urea. The reactant fluid is mixed with exhaust gas flow, and urea is decomposed to ammonia and CO 2 due to heat of the exhaust gas. The formed ammonia and exhaust gas flow into the SCR catalyst, where the ammonia reacts with NO and NO 2 molecules, converting the NOx molecules into harmless nitrogen (N) and water vapour. The reactant fluid is often called AdBlue or diesel exhaust fluid (DEF).

Only genuine DEF (DIN 70070- or ISO 22241-certified) can be used as the reducing agent. If the urea quality sensor detects a problem related to urea quality, the sensor alerts the engine control system with a CAN message, causing the engine to run under degraded mode.


Model

Page

T4 HiTech

6

9

17

7

1

8 18

7 16

6

4

19

10

11

3

5

2

13

14 12 GUID-24F116A9-C481-4DDD-87D0-188DEFE867FD

15


1. 2. 3. 4. 5. 6. 7. 8. 9.

DEF tank module sensor (B16M) Valve, AdBlue dosing (Y3M) Breather filter Tank module (AdBlue level + temp.) AdBlue/DEF tank (70 litres) Additional expansion tank Electric heater of the pressure line (outlet) (R1M) Electric heater of the return line (R2M) Electric heater of the suction line (R3M)

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Coolant circulation valve, AdBlue tank heating (Y4M) Coolant circulation return line, AdBlue heating Exhaust gas temperature sensor, upstream (B12M) Diesel Oxidation Catalyst (DOC) Nitrogen oxide (NOx) sensor, upstream (B14M) Exhaust gas temperature sensor, before DOC (B24M) Supply module (A3M) Exhaust gas temperature sensor, downstream (B13M) NOx sensor, downstream (B15M) Selective Catalytic Reduction (SCR) catalyst inside the exhaust pipe

Model

Page

T4 HiTech

7

The coolant fluid for the AdBlue/DEF tank heating is taken from the pressure side of the water pump. The return line from the AdBlue/DEF tank goes to the cooling hose of the cabin and continues from there to the suction side of the engine water pump.

The engines are equipped with two NOx sensors, one located before the DOC catalyst (upstream exhaust gas flow), andcontrol the other after the catalyst (downstream exhaust flow). These sensors separated in the emission software by SCR their controlled area network (CAN) gas addresses. A NOx sensorare contains a sensor electronic control unit (ECU) and a separate sensor head, where the sensing element is located.

The supply module transfers AdBlue/DEF additive from the tank and pressurises it. The nominal system pressure is 9 bar relative. The supply module also contains the pre-filter and main filter for AdBlue/DEF. The supply module is equipped with internal electrical heaters.

The dosing module contains an electrically operated solenoid valve which injects the required amount of AdBlue/DEF through the nozzle when being powered by the engine control unit (EC). The correct AdBlue/DEF injection amount for each operating condition is calculated by the EC software for the optimal reduction of NOx. The dosing module is installed onto the exhaust line and needs to be cooled when the engine is running. Cooling is done by engine coolant circulated by engine water pump.


Model

Page

T4 HiTech

8

8 7 6 5

4

10

3

2 1

7 9

5 6 7

10 9

11

GUID-F289C44C-015A-4B2D-830A-F981FAB55AE9

12

13


Model

Page

T4 HiTech

9

1. 2. 3. 4. 5. 6. 7. 8. 9.

AdBlue/diesel exhaust fluid (DEF) backflow connector O-ring AdBlue/DEF outlet connector Supply module Main filter element (including O-rings) Equalising element (includes sealing surface) Filter cover Pressure compensation element AdBlue/DEF inlet connector + filter

10. 11. 12. 13.

Coolant connectors Sealing plate Nitrogen oxide (NOx) sensor Catalyst temperature sensor

• • • •

Transfers AdBlue/DEF from tank and filters and pressurises it. The nominal system pressure is 9 bar. Heated by electricity. Controlled by the electronic engine control unit (ECU). The selective catalytic reduction (SCR) system supply module main filter (40 µ mesh filter) must be changed every 1 200 hours or yearly, whichever occurs first. Pre-filter in the inlet channel of the supply module (100 µ mesh filter). This is a service-free filter and should be changed only if needed. The part number contains the complete connector. The outlet and backflow connectors are replaceable.

•

•

• •

• • •

The dosing module is installed in the exhaust pipe between the turbocharger and the SCR catalyst. The dosing module contains an electrically operated solenoid valve which injects the required amount of AdBlue/DEF through the nozzle of the module when being powered by the ECU. The dosing module is installed onto the exhaust line and needs to be cooled when the engine is running. Cooling is done by engine coolant, circulated by the engine water pump. The correct AdBlue/DEF injection amount for each operating condition is calculated by the ECU software for optimal NOx reduction. The DEF consumption during Stage 4 / Tier 4 is about 6-7% of the fuel consumption, depending on the duty cycle and the engine specification. Filter in the inlet connector (40 µ mesh filter). Not replaceable. Replaceable coolant connectors. Dosing module coil resistance is 11.4…12.6 Ohm at +25°C.

• • • •

Contains an ECU sensor and a separate sensor head where the sensing element is located. NOx sensors communicate with the ECU via the controlled area network (CAN) bus. Tightening torque of the sensor head is 50 Nm. Installed to the exhaust line, one before the diesel oxidation catalyst (DOC) and another after the SCR catalyst (two sensors).

• •

Positive Temperature Coefficient (sensor resistance increases when warming up). Installed to the exhaust line: one before the diesel oxidation catalyst, one before the SCR catalyst and one after the SCR catalyst (three sensors). Tightening torque of the sensor is 40 Nm. Nominal resistance:

• •

• •

at +25°C = 220 at +700°C = 679


Model

Page

T4 HiTech

10

B2

R1M R3M R2M

E45

Y4M

X6M

B16M

A3M

GUID-D66B8D33-168E-4D13-9665-44F977BE6E4A

A3M

DEF supply module

B2

Sensor, fuel level

B16M

Sensor,DEFtankmodule(levelandtemperature)

E45 R1M

Doorstep light Heater, DEF pressure line

R2M

Heater, DEF return line

R3M

Heater, DEF suction line

X6M

Connector, engine SCR - system

Y4M

Solenoid valve, DEF tank heating


SCR tool kit

SCR tank backup case

837091048

837091079

Model

Page

T4 HiTech

1


Before you start:

4

3

2 6 1

3 5

GUID-655B6EB9-9138-46D3-A47A-37C3970F7F23

1. Attachment bolt 2. Exhaust pipe cover 3. Dosing module attachment 4. hoses 5. DOC Uppercooling heat cover 6. DOC support bolts

Model

Page

T4 HiTech

1


Model

Page

T4 HiTech

2

The selective catalytic reduction (SCR) aftertreatment system contains copper-zeolite. Copper-zeolite is not classified as hazardous. The SCR aftertreatment system is installed in the muffler. The system is not hazardous to health under normal use and handling. When the SCR aftertreatment system is handled in such a way that there is a risk of exposure to dust, safety precautions must be taken. Such work includes, for example, opening the aftertreatment system, machining and disposing of the aftertreatment system.

• • • •

Inhalation: If dust is inhaled, the affected person must be moved to fresh air. If a considerable amount of dust has been inhaled, seek medical help. Contact with eyes: Rinse eyes with water for 15 minutes and with eyelids held open. If irritation continues, seek medical help. Contact with skin: Wash with soap and water. Take off contaminated clothes. Swallowing: If you swallow a large amount, rinse mouth and then drink plenty of water.

Copper/zeolite is not acutely harmful to aquatic organisms. The product has not been tested.

All dust and spillage must be gathered in a container for recycling or disposal in accordance with local regulations. Used catalysts may have different hazardous properties than the srcinal products. When an SCR aftertreatment system is no longer used, it must be disposed of in accordance with applicable EU regulations, national regulations or local regulations.


Model

Page

T4 HiTech

3

1

: In extremely dusty conditions the selective catalytic reduction system breather must be changed more frequently. : The area around the filter cover must be checked for cracks. 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 it must be replaced. : All sealing surfaces on the filter cover, equalizing element, filter element and supply module housing must be absolutely clean and undamaged. : Do not install used or wet filter or equalizing element. Danger of engine damage and poor filtration.

GUID-31E019BA-4BDC-4D7C-BF3D-E4AAA33BEE49

1. : Do not use mineral or silicone oils or greases when assembling the filter seals. All seals have a non-stick coating.

Fastening screw

Unscrew the two fastening screws.

1

2 1

2 3

3 GUID-27F56ED7-221E-4F71-9809-6FD5F44DEC77

GUID-52E6A0F5-9A9B-4087-AC13-9D60C4C03F57

1. 2. 3.

Fastening screw Protection plate Breather

Unscrew the fastening screws and remove the protection plate first. Fit the protection plate after changing the breather.

1. 2. 3.

Filter Equalizing element Filter cover

Use 27 mm wrench.


Model

Page

T4 HiTech

4

The tightening torque is 20-25 Nm.

Fasten the steps with the two fastening screws. 1 3

Before you start:

Make sure that cleaning cloths and protection caps for hydraulic and electrical connectors are available. Reserve a suitable container for the DEF which can drain from the hoses. : The area around the filter cover must be checked for cracks. 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 it must be replaced.

2 GUID-E1B0E38F-1D2F-4933-AAEF-9787B59EA0C6

1. 2. 3.

Bolts for attaching the module Hydraulic connectors Electrical connector

Tighten the hydraulic connectors to 4.5 ± 0.5 Nm. 1

Before you start:

GUID-31E019BA-4BDC-4D7C-BF3D-E4AAA33BEE49

1.

Screws for attaching the steps


Model

Page

T4 HiTech

5

•

1

2

1

GUID-6885F4CA-8848-498C-9DC7-8CCA65F2BFA1

1.

Sealing plate

3 GUID-D64246DB-5ECD-4EE1-85C1-44F3ED40C816

•

2

3

1 GUID-41D1B1EC-E5DF-403E-B062-E904E9061AE3


Model

Page

T4 HiTech

6

Before you start: The EEM4 engine management system pressurizes the dosing system after the exhaust line temperature increases to approximately 120°C. If the first start of the dosing system does not pressurize the system, the EEM4 system gives the pressure buildup fault code.

When the SM lifting capacity test does not give an underpressure of at least 0.2 bar:

During a failure, diesel exhaust fluid (DEF) dosing is not possible, which causes too high exhaust emissions and sets limits to engine power.

DEF seeding

•

Inlet connector (including prefilter) • •

•

Examinev isually Replace

Manual vacuum pump

If the seeding is not successful or if the seeding is successful but the fault code is still in effect:

DEF

If the seeding is successful:

•

• • •

Blockages

Air leak

Level sensor Freezin g Conta minatio n

•

Breath er Inlet filter in the tank Lines

•

SM lifting capacit y test is satisfac tory

•

Ifthe fault code about DEF overpre ssure stays in effect,

•

•

•

• •

Tank sensor Connec tors Lines

Ifthe SM lifting capacit y test is unsatisf actory, change the SM

change the backflo w valve Solution found

SM lifting capacity test gives an underpressrue of at least 0.2 bar: DEF • • •

Lever sensor Freezing Contamination

Blockages • • •

Breather Inlet filter in the tank Lines

Air leak •

Tank sensor

• •

Connectors Lines

Solution found

The vacuum pressure gauge is in the SCR tool kit 837091048.


The supply module must give an underpressure of at least 0.2 bar.

Before you start:

Model

Page

T4 HiTech

7

Use the pump until DEF comes out to the suction pump container. This makes the pump membrane operate again. This also blows the possible dirt particles from the membrane chamber.

When the DEF goes into the supply module membrane, the pressure of the dosing system starts to increase normally. The test will start only if the engine is not in operation and the catalyst temperature is below 100°C.

Make sure that the inlet connector is not clogged. Replace the inlet connector if necessary.

If the supply module lift capacity test is

1

satisfactory, you have the solution to the pressure buildup failure.

There is a check valve inside the backflow connector. If the check valve is clogged, the pressure control of the supply module is interrupted.

Send the broken supply module to AGCO for inspection and install protective tubes on the DEF connectors to give protection against dirt and oxygen. GUID-D037DED9-AC4B-4BC8-87E0-308DBE962183

1.

Place of the pressure gauge

The normal pressure is 8-9 bar. If the pressure is still below the normal pressure or if the pressure is normal but the fault code still shows, the solution is the same as if the SM lift capacity test was satisfactory.

The manual vacuum pump is in the SCR tool kit 837091048.


Model

Page

T4 HiTech

8

3

• • • •

2

• 1

If the value is not close to 0%, the cause can be a DEF tank sensor connector corrosion, a DEF tank sensor failure or a wiring harness failure. • Make sure that the DEF tank level reading on dashboard changes accordingly, showing a full DEF tank.

4

GUID-D01DEC02-E4EF-46E3-8170-1A88D1A2FB85

The dosing rate test indicates if the SCR dosing system operates correctly and the dosing quantity is at the correct level. A decreased dosing rate is a possible cause for the fault code SPN 4090 FMI 16, SCR system malfunction: NOx emission too high.

1. 2. 3. 4.

Electric connector Connection to the DEF pressure line Coolant connections Sealing plate

Do not close the measuring jug cover too tightly. The ventilation of the jug during the test is possible if there is a small air hole on the jug.


Model

Page

T4 HiTech

9

• • • The tolerance is 165-202 milliliters. •

The service life and the performance of the SCR catalytic converter depend on the quality of DEF. DEF must be of the optimal mixture ratio of 32.5% urea and 67.5% demineralized water. DEF must not have mineral oils, particles or other contamination in it.

Use the SCR system emptying test of the EDT.

The SCR tool kit includes a refractometer that you can use to examine the urea-water mixture ratio. The SCR tool kit also includes an oil test paper that you can use to find dirt, such as petrol, heating oil and lubricating oil.

If there are other failure codes in the error log, contact an authorized Valtra workshop. • • •

•

• • • • •

•

•

• •

If there is no oil in the fluid, the test paper is not wet or discolored but stays pale blue. If there is oil in the fluid, the paper becomes dark blue. The intensity and size of the spots are an indication of the amount of oil.

Cooling system

Model

Page

T4 HiTech

1

Technical specifications..................................................................................1 Cooling system.......................................................................................... 1 Thermostat.................................................................................................1 Cooling system............................................................................................... 2 Coolant quality requirements.......................................................................... 4 Coolers............................................................................................................5

Coolant pump tools.........................................................................................1

Changing the thermostat.................................................................................1 Checking the thermostat.................................................................................2 Reconditioning the coolant pump....................................................................3

Cooling system 7.4.2015

Model

Page

T4 HiTech

1

Pump

Centrifugal

Radiator

Pressurisedwithexpansiontankregulatedbypressurecap

Thermostat

2 thermostats: 79°C and 83°C

Fan

Thebelt-drivenfaniscontrolledbytheengine'scontrolmodulefor

Coolant

precise fan speed modulation Enginecoolantmixedwithwater.ASTMD6210TypeI-FF,ASTM D3306. In first fill, OAT-coolant (Organic Acid Technology) used, not recommended to mix with old type of coolants.

Coolant,Valtragrade

ValtraCoolant

Coolant volume

28 litres

Coolant temperature in normal 1)

use 1)

90-106°C

The coolant temperature gauge goes to the red area when the coolant temperature increases to 106°C. If the coolant temperature increases to 113°C, the alarm operates. If the temperature stays at 113°C for 30 seconds, the engine stops.

ø67 83°C mm /

83°±2°C

95°C

8.0 mm

ø54 79°C mm /

79°±2°C

94°C

7.5 mm


1

2

4 GUID-92B9DA3B-BB38-4277-B45C-68F9BC7F4655

1. 2. 3. 4. 5. 6.

Bypass pipe Expansion tank Thermostats Radiator Coolant pump Oil cooler

3

5

6

Model

Page

T4 HiTech

2


Model

Page

T4 HiTech

3

1 2

GUID-87FCEC18-D995-44AE-985E-F95635CFBADB

1. 2.

Double-acting thermostat, opening temperature 83°C Single-acting thermostat, opening temperature 79°C

The coolant pump is attached to the front face of the cylinder block and the thermostat housing is mounted above it. One of the two thermostats steers the bypass of coolant liquid. This arrangement ensures a steady warming-up of the engine under all conditions. The thermostats differ in types and opening temperatures. When the coolant temperature is below the thermostat opening temperature, the coolant circulates through the bypass hole into the coolant pump. The smaller, single-acting thermostat opens at 79°C, letting one part of the coolant into the radiator. Following the load increase, the other thermostat opens at 83°C. This is a double-acting type which closes the bypass hole when it opens and directs the coolant into the radiator. These engine models do not have any separate winter-type thermostats.

18.9.2015 Cooling system 29.2.2016

Model

Page

T4 HiTech

4

The coolant used must meet the demands of the standard ASTM D6210 Type I-FF or ASTM D3306. •

• •• •

The cooling mixture must consist 40-60% of ethylene glycol- or propylene glycol-based antifreeze and water. The best proportion is 50% antifreeze liquid and 50% water. The cooling mixture must not consist of water only. The water used must be mechanically cleaned and not too acidic (for example swamp water) or too hard (calciferous well water). The proportion antifreeze (theglycol-based frost resistance) in the must coolant be checked periodically. Ethylene glycol-ofand propylene antifreeze notmust be mixed. If you use long drain interval OAT-coolant (Organic Acid Technology), the coolant must be changed every 5 years. If you use another type of coolant, the change interval is 2 years. We recommend that you do not mix the OAT-coolant with any other type of coolant.


Model

Page

T4 HiTech

5

2

1

3 5

4

6

GUID-E6C72367-8A6C-47C8-AB8F-0EF264AF0A9F


1. 2. 3. 4. 5. 6.

Engine intake air cooler Transmission oil cooler Fuel cooler Front power take-off (PTO) oil cooler (extra equipment) Engine coolant radiator Air conditioning cooler (extra equipment)

Model

Page

T4 HiTech

6


910193200

Model

Page

T4 HiTech

1

Pullerforcoolantpumpimpeller

GUID-416DC9A6-87C1-486D-B688-F0E5B5201547

920197870

Driftforfittingcoolantpumpwaterseal

GUID-F6744999-EFEB-458E-9E5D-E1A504847AEF

920189320

Driftforfittingcoolantpumpbearing

GUID-2C1C6AE1-B4DF-440D-9FEA-171EB0F5D269

920187410

GUID-DC7A1E6D-1343-4D0E-8482-2B6E987CB5B6

Socket for coolant pump nut


The coolant level must be below the thermostats.

Use M8 studs (2 pcs) as guides.

Model

Page

T4 HiTech

1


Ensure that the thermostat does not touch the sides or the bottom.

The opening must begin in less than 20 seconds.

The thermostat must open fully in less than 50 seconds.

Model

Page

T4 HiTech

2


Model

Page

T4 HiTech

3

Use the special tool 920197870. Use coolant as lubricating liquid between the shaft and the seal.

1

Use the special tool 910193200. •

• GUID-C1C02632-BE84-47E0-B133-773453363E21

Use the drift.

Replace faulty or worn parts with new ones. If the pump bearings have to be changed, use the reconditioning kit. The kit includes all the needed seals.

Use heat-resistant ball bearing grease (NLGI 2).

Fit the shaft and the ball bearings so that they do not transmit the pressure.

1.



Support the shaft at the other end while pressing the impeller. Make sure that the shaft can rotate freely. The impeller mounting depth depends on the impeller diameter.

97

Page

T4 HiTech

4

The tightening torque is 120 Nm. : The belt pulley fixing screw has a lefthanded thread.

25.5 0.2 ±

120

Model

1

0.2± 8

130

27.4 0.2 ±

156

30.4 0.2 ±

1

GUID-DDE4DE28-D497-486F-8105-1D1805FEF2E7

1.

Belt pulley fixing nut

Use guide pins (Ø 8.5 mm) in the holes. The tightening torque is 35 Nm. GUID-C710A72F-14D5-4011-97C2-9348142BBF8C

1.

Impeller mounting depth 1

2 GUID-4E9C2D20-1C6D-42C6-B873-940EAFC2BBD5

1. 2.

Rear plate fixing screws Guide pin holes

Electronic engine management

Model

Page

T4 HiTech

1

Electronic engine management system.......................................................... 1 Electrical equipment; engine...........................................................................2 Electrical equipment; engine auxiliary functions............................................. 4 Engine sensors............................................................................................... 6 Starting control................................................................................................8 Engine speed control.................................................................................... 10 Low idle speed..............................................................................................11 EcoPower......................................................................................................12 Drive pedal....................................................................................................14

Engine control unit tools..................................................................................1

Measuring the voltage drop between battery and starter motor..................... 1 Changing the engine control unit.................................................................... 2 Fitting sensor and vehicle connector wiring sets............................................ 3 Connecting the injector wiring.........................................................................4

Electronic engine management 7.4.2015

Model

Page

T4 HiTech

1

The basic function of electronic control of the engine is the continuous adjustment and measuring of engine load, fuel quantity and rotating speed. Additional functions include cold-start automatics, engine-protecting automatics and the selective catalytic reduction (SCR) system control. The central unit of the electronic control system continuously receives signals from sensors that measure different engine functions, such as rotating speed, oil pressure, boost pressure and fuel and coolant temperature. The control unit receives the relevant information about the engine load requirement from the transmission or cabin through the CAN The electronic code numbers or bus. a diagnostic light. control unit EEM4F also makes it possible to have wide diagnostics through Any adjustment and repair work to the injection system or the engine control unit should only be carried out by a representative authorised by Valtra service. When performing any service or repair work, only use srcinal spare parts. Inadequate or delayed service and the use of parts other than srcinal spare parts will invalidate the responsibility of Valtra Inc. with respect to the fulfilment of the emission requirements.


Model

Page

T4 HiTech

2

F53 Y15M Y16M

X123 X7M

K8M

Y14M

M5M

R5M B5M

Y13M

Y7M

Y12M Y11M

M6M

B7M B20M

B10M B4M

B9M

X5M

B11M

Y17M

A1M

B6M A2M B19M

GUID-CF929FB3-CB45-49C6-9488-4B72E80EB89C

A1M

ECU, EC (engine control unit) / Connector, tractor

A2M

Connector, EC (engine control unit), engine

B4M

Sensor, fuel temperature

B5M

Sensor, boost pressure temperature /

B6M

Sensor, engine oil pressure

B7M

Sensor, common rail pressure



B9M

Sensor, coolant temperature

B10M

Sensor, crank speed

B11M

Sensor, cam speed

B19M

Sensor, fuel prepressure

B20M

Sensor, fuel filter pressure

F53

Fuse, 250A, grid heater

K1M K8M

relay Start Relay, grid heater

M5M

Actuator, waste gate

M6M

Model

Page

T4 HiTech

3

Throttle valve

R5M

heater Grid

X5M

Connector, cross-wiring, tractor engine -

X7M

Connector, cross-wiring, tractor engine -

X123

Connector, engine actuators -

Y7M

Controlvalve,enginepressurecontrol(PCV)

Y11M...Y16M

Fuelinjectors,enginecylinders1-6

Y17M

Controlvalve, highpressure pump(MPROP)


X62

B13M

B15M

B24M B14M

X6M

S2M

B12M

X8M

R6M

X7M GR7

M1

B12M

G1

F53

B2C/1

X2M

Y3M

K1M S1M

F53

Y2M X3M

G2

B2M

B1M K8M A1M X5M

GUID-BEF7D460-0973-4409-A557-4CA6B0F18A92

Model

Page

T4 HiTech

4


Model

Page

T4 HiTech

5

A1M


B1M

Sensor, water fuel in

B2M

Control module, cooling fan

B2C/1

Connector, wheel angle sensor

B12M

Sensor,exhaustgastemperature,upstream

B13M

Sensor,exhaustgastemperature,downstream

B14M B15M

Sensor, NOx upstream Sensor, NOx downstream

B24M

Sensor,exhaustgastemperature,beforeDOC(Catalyticconverter)

F53

Fuse, 250A, grid heater

G1

Battery

G2

Alternator

GR7

Grounding bolt, frame

K1M

relay Start

K8M

Relay, grid heater

M1

Starter

R6M

Terminating resistor CAN3, engine end

S1M

Pressure switch, AC compressor

S2M

Pressure switch, air filter vacuum

X2M

Connector, engine

X3M

Connector, engine cooling fan

X5M

Connector, cross-wiring, tractor—engine

X6M

Connector, engine — urea module

X7M

Connector, cross-wiring, tractor—engine

X8M

Connector, exhaust pipe

X62

Connector, bonnet

Y2M

Solenoid valve, AC compressor

Y3M

Solenoid valve, DEF dosing


B13M

B15M

Model

Page

T4 HiTech

6

B24M B14M

B11M

B2

B12M

B2C/1

B5M

B9M

B16M

B2M

B3 B10M

B1M B20M B7M

B19M B6M

GUID-4325215A-4953-4571-BFCB-DCB0D3BD57EE

B4M


B1M

Sensor, water fuel in

B2

Sensor, fuel level

B2C/1

Sensor, wheel angle

Model

Page

T4 HiTech

7

B2M

Control module, cooling fan

B3

Sensor, ambient temperature (EC)

B4M

Sensor, fuel temperature

B5M B6M

Sensor, boost pressure temperature / Sensor, engine oil pressure

B7M

Sensor, common rail pressure

B9M

Sensor, coolant temperature

B10M

Sensor, crank speed

B11M

Sensor, cam speed

B12M

Sensor,exhaustgastemperature,upstream

B13M

Sensor,exhaustgastemperature,downstream

B14M

Sensor, NOx upstream

B15M

Sensor, NOx downstream

B16M

Sensor,DEFtankmodule(levelandtemperature)

B19M

Sensor, fuel prepressure

B20M

Sensor, fuel filter pressure

B24M

Sensor,exhaustgastemperature,beforeDOC(Catalyticconverter)


A1P

20 25

Page

T4 HiTech

8

S36

20

5

Model

30 40 5

0

30

50 0

S T

S T O P

O P

Q1 S9 S1W

A1M

N CA

EC

K7M F2M F3M F12M

K1M M1

G1

GUID-ECDCBADF-9E97-4016-9960-6C8355C4A08C

The control unit EC has a constant current through fuse F3M when the ignition switch is turned to

(ACC)

position. When the ignition switch (Q1) is turned to (power on) position, the control unit receives the ignition switch signal through fuse F12M. The control unit engages the relay K7M. Current to the control unit goes now through fuse F2M. When the ignition switch is turned to (start) position, the control unit engages the starter relay (K1M). The starter motor (M1) engages when the starter relay is engaged. The engine can be started only with the clutch pedal pressed down. Start enabled pin on the control unit EC is then grounded through the clutch pedal limit switch S9 (S1W).

The control stop switch (S36) must be switched off before starting. The control stop switch is additional equipment. The control stop automatically stops the engine if the stop light in the instrument panel is lit. Instrument panel earths the pin with help of:


• • • • • •

Model

Page

T4 HiTech

9

engine oil pressure (B6M) engine temperature (B9M) gearbox oil pressure (S55) gearbox oil temperature (B14) hydraulic oil temperature (B23) hydraulic oil level (S54)

Message “CONTROL STOP ON!” is shown on the instrument panel display.

A1M


A1P

Instrument panel

F2M

Fuse, engine ECU

F3M

Fuse, engine ECU wake up

F12M

Fuse, engine ECU ignition key signal

G1

Battery

K1M

Relay, starter relay

K7M

Relay, engine ECU main

M1

Starter

Q1

Ignition switch

S1W

Limit switch, rear clutch pedal

S9

Limit switch, front clutch pedal

S36

Switch, control stop


Model

Page

T4 HiTech

10

The highest engine speed demand coming from the drive pedal, hand throttle or cruise control system is considered the engine speed requested by the driver. The driver's request is ignored if there is an rpm demand coming from outside the engine control unit (EC). Such demands include, for example, shifting automatics during the so-called double-clutching. The engine speed request is also limited based on the maximum driving speed.


Model

Page

T4 HiTech

11

EC A1M

TC S41 A1A

N CA

A2C

SECU

S5W

S6W S7W

GUID-423E3CCB-9A5A-4D60-9214-32A4F7F8F24D

When parking brake is engaged, the idle speed is 650 rpm. The parking brake is applied with the power shuttle lever. When applied, the control unit TC switches the parking brake on and requests the lower idle speed from the engine control unit EC. The parking brake indicator light is lit when the parking brake is engaged.

A1A


A1M


A2C

ECU, SECU (steering control unit) (additional equipment)

S5W

Switch,rear shuttlelever,forward(additional equipment)

S6W

Switch,rear shuttlelever,reverse(additional equipment)

S7W

Switch,rear shuttlelever,parking (additional equipment)

S41

Switch,frontshuttlelever


Model

Page

T4 HiTech

12

ECO

S140

A4A

EC

IO1

A1M

TC A1A

N CA GUID-2BC374A1-FC3B-44CC-8E1C-13F9CCC03B26

p H

m N

1100

1500

1 2

RPM

1 700

1 900

3 4

GUID-2C69A7CD-0F25-4825-B550-A42B611FDB0E

1. 2. 3. 4.

Engine power, standard mode Engine power, EcoPower mode Engine torque, standard mode Engine torque, EcoPower mode

When the EcoPower mode is engaged, the engine speed is approximately 200 rpm lower than in the standard mode.


A1A

Model

Page

T4 HiTech

13


A1M


A4A

ECU, IO1

S140

Switch, EcoPower mode


EC

Model

Page

T4 HiTech

14

SECU

A2C

A1M

X19 X40

TC A1A

N CA

B2W

B15

GUID-E3E953FB-03FC-4BD3-B7F6-8A560D18B2AC

The drive pedal sensor (B15 and B2W) sends a stereo signal to EC and TC. When the drive pedal is pressed, EC sends a message to TC via CAN bus on the percentage the drive pedal sensor channel 2 has been pressed. Channel 1 of the drive pedal sensor is connected to TC. TC compares the position data from channel 1 to the position data EC sends and uses the smaller value. EC calibrates automatically the minimum and maximum position of the drive pedal. The stereo signal is cross connected. The voltage of one channel increases and the voltage of the other channel decreases when the pedal is pressed.

A1A


A1M


A2C

ECU, SECU (steering control unit) (additional equipment)



Model

Page

T4 HiTech

15

B2W

Sensor,reardrivepedal(additionalequipment)

B15

Sensor, front drive pedal

X19

Connector, front housing-cab

X40

Connector, front housing-cab


Electronic Diagnostic Tool (EDT)

GUID-742F03E7-287C-4621-A592-DEF296FE2387

Model

Page

T4 HiTech

1


1

3

V V

2

V

GUID-D4608D1A-6F58-4678-9985-6092D927ED2F

1. Measurement between battery plus pole and starter motor solenoid output 2. Measurement between battery minus pole and starter motor earth 3. Measurement between starter motor solenoid input and output

The maximum voltage drop is 0.5 V.

The maximum voltage drop is 0.1 V.

The maximum voltage drop is 0.3 V. If the voltage drop is greater than the maximum value given for each measurement, the reason is oxidised connectors or wires and their contact point. If the measurements are in order but the starter motor does not run, the starter motor may be damaged.

Model

Page

T4 HiTech

1


Model

Page

T4 HiTech

2

Before you start: Provide the engine serial number when ordering the new engine control unit (ECU). The engine serial number can be found on the type plate of the ECU.

Do not touch the connector poles.

Check that the bracket rubber dampers work. Change the rubber dampers if necessary. The tightening torque is 30 Nm.

Tighten the screws in the correct sequence. The earth wire is located under the upper right fastening screw. The tightening torque is 10 Nm. 4

7 1

GUID-A759A8F0-A859-4676-96CB-B625CD775B1F

5

6

3

2

5 8

1

3

GUID-C6287356-DFDD-437F-8A2D-37150D09DEB6

After you finish: The engine control unit (ECU) is delivered with the 2

4

GUID-66F725A1-CCC6-4F6D-9057-047466AFE0F5

1. 2. 3. 4. 5. 6. 7.

Rubber damper Rubber damper fixing screw Bracket Engine control unit fixing screw Engine control unit Plastic cover fixing screw Plastic cover

6

7

specified software version already loaded in it.


: The wiring sets are delivered as complete sets; the connectors are not available as separate spare parts.

2 1 GUID-8BE1810D-6042-4EF6-8F13-7A597430D3CD

1. Sensor wiring set 2. Vehicle connector wiring set

Use bands.

Use bands. : Avoid too sharp turns and do not damage the wiring sets with sharp parts.

Model

Page

T4 HiTech

3


Before you start: : The wiring sets are delivered as complete sets; the connectors are not available as separate spare parts.

2

1 3

4

GUID-476FB51B-6219-4BF0-AF1A-8A027691B20F

1. 2. 3. 4.

Injector Wire connector Lock washer Nut

• The wires can be connected to the injectors in any order.

If the wires get to move, there may be oil leaks from the connectors.

Use the special tool 920179670. : If the connector has to be removed from the frame, the nut and the lock washer should be changed.

Model

Page

T4 HiTech

4

Powered front axle

02 Axles Air suspension of front axle

Powered front axle

Model

Page

T4 HiTech

1

Powered front axle Dana 740/560.................................................................. 1 Technical specifications.............................................................................1 Front axle, Dana 740/560.......................................................................... 3 Planetary reduction....................................................................................4 Differential..................................................................................................5 Adjusting the differential and pinion shaft.................................................. 7 Powered front axle Dana 740/561.................................................................. 8 Technical specifications.............................................................................8 Front axle, Dana 740/561........................................................................ 10 Planetary reduction with brakes...............................................................12 Differential................................................................................................15 Adjusting the differential and pinion shaft................................................ 17 Powered front axle Dana 750/570................................................................ 18 Technical specifications...........................................................................18 Front axle, Dana 750/570........................................................................ 20 Planetary reduction..................................................................................21 Differential................................................................................................22 Adjusting the differential and pinion shaft................................................ 24 Powered front axle Dana 755/509................................................................ 25 Technical specifications...........................................................................25 Front axle, Dana 755/509........................................................................ 27 Planetary reduction..................................................................................28 Differential................................................................................................29 Adjusting the differential and pinion shaft................................................ 31 Powered front axle Dana 755/510................................................................ 32 Technical specifications...........................................................................32 Front axle, Dana 755/510........................................................................ 34 Planetary reduction with brakes...............................................................35 Differential................................................................................................38 Adjusting the differential and pinion shaft................................................ 40

Front axle tools............................................................................................... 1 Locally prepared tools................................................................................1

Planetary reduction gear.................................................................................1 Planetary reduction gear............................................................................1 Disassembling the planetary reduction gear..............................................2 Assembling the planetary reduction gear.................................................. 6 Steering knuckle and steering sensor...........................................................12 Steering knuckle and steering sensor......................................................12 Disassembling the steering knuckle and steering sensor........................13 Assembling the steering knuckle and steering sensor.............................17 Steering cylinder........................................................................................... 24 Steering cylinder...................................................................................... 24 Disassembling the steering cylinder........................................................ 25 Assembling the steering cylinder............................................................. 28 Differential.....................................................................................................33 Differential unit.........................................................................................33 Disassembling the differential unit........................................................... 34 Assembling the differential unit................................................................38 Bevel pinion.................................................................................................. 45

Powered front axle

Model

Page

T4 HiTech

2

Bevel pinion............................................................................................. 45 Disassembling the bevel pinion............................................................... 46 Assembling the bevel pinion.................................................................... 48

20.1.2015 Powered front axle 13.3.2015

Model

Page

T4 HiTech

1

Powered front axle, Dana 740/560

– Differential

2.923

– Planetary reduction

6.000

– Total gear ratio

17.538

Numberofteeth(crownwheel/pinion)

13/38

Steering arc, adjustable

max 55°

Axle turning

± 7°

Caster

0°

King pin inclination (KPI)

5.5°

Camber

1°

Toe-in

mm 0-2

Flange distance

1900 mm

Differential Planetaryreduction

Dana 740/560

Valtra Axle LS

80W-90

GL-5 LS

ValtraAxleorValtraAxleLS

8.5

GL-5orGL5LS

2.0x 2


Model

Page

T4 HiTech

2

Torques and liquids

10 Nm, Loctite 270

220 Nm, Loctite 270

202 Nm

12 Nm, Loctite 243

202 Nm

200 Nm, Loctite 243

1 130 Nm, Loctite 270

270 Nm, Loctite 270

2

2

270 Nm

3

3 Nm, Loctite 243

190 Nm

3

300 Nm

2 202 Nm

2

1 90 Nm

4 75 Nm

52 Nm GUID-6F554068-CF80-4BDE-B88A-09DAD56670E2

1. 2. 3. 4.

Sealing compound (lithium-based grease) Bearing cap SAE 80W–90 oil Corrosion preventive assembly paste or lithium based grease

In addition to bearing cap and steering cylinder, lithium-based grease is applied to bearings, sliding parts and used to lubricate seals or parts during assembly. Setting values Press fit of the king pin standard value (not loose)

0.7-0.8 mm

Rolling resistance for pinion shaft bearings (measured using torque meter): – Bevel pinion shaft bearings without seal ring Table continued on next page

2–4 Nm


– Bevel pinion shaft bearings, seal and differential bearings

2.7–5.4 Nm

Tolerance between the bevel gear teeth (measured from input flange bolt hole using a dial indicator)

0.36–0.48 mm

Axial clearance (between axle housing and pivot bearing brackets)

0.1–1.1 mm

Model

Page

T4 HiTech

3

2204 1900 1636

o

5 3 3

1

5.5

o

5.5

1

2 4

55

°

M ax

3

1

5

Ø72 x Ø38

TOE IN 0...2 mm

6

GUID-0D7AF10D-727A-44B5-BB86-D3F7936DE4D2

1. 2. 3. 4. 5. 6.

Oil draining / filling plug for planetary reduction Oil draining plug for differential Oil checking / filling plug for differential Steering angle sensor Grease nipple Differential lock

o


2

1

Model

Page

T4 HiTech

4

3

4

5

6

3

3

GUID-6E81042B-AE9E-4F53-98C3-94063BDE9337

1. 2. 3. 4. 5. 6. 7.

Shim calculation Shims Bearing Double U-joint shaft Planet gear, 3 pcs Steering angle sensor Oil draining / filling plug

King pin preload = 0.7–0.8 mm Calculate the difference between sizes “first step shim” , “measured backlash” and “preload”. Example:

7


First step shim = 2 mm. Measured backlash = 0.5 mm. S= 2 mm - 0.5 mm - 0.8 mm = 0.7 mm

21

5 6 2 1 2 7 1 8

GUID-8BB55F5A-B4F1-496A-9083-7ABBBC68226E

2

432 1

Model

Page

T4 HiTech

5


1. 2. 3. 4. 5. 6. 7. 8.

Shims Bearing Friction discs Piston Crown wheel Pinion shaft Axial clearance Pinion nut

Model

Page

T4 HiTech

6


Model

Page

T4 HiTech

7

• B

1

•

D 2

3

• S

C=A±B Example: C = 1.1 - 0.1 = 1, C = 1 mm

4

5

S = C - (D) Example: S = 1 - (+0.1) = 0.9, S = 0.9 mm

6

Tighten the nuts in two stages using the crisscross method to 200 Nm.

7

Use a torque meter on the pinion to check that the torque increases by 0.7–1.4 Nm as a result of the differential bearing preload. Example: Pinion torque 2–4 Nm + differential 8

9

GUID-85090993-2AB8-4A38-AE30-3757990C28F3

1. 2. 3. 4. 5. 6.

Old pinion nominal dimension (B) New pinion nominal dimension (D) Amount of shims (S) Shims (0.6 mm) Central body and arm joint Shims (1.2 mm)

7. No seal 8. Torque meter 9. Bar-hold and dial gauge on pinion

65 mm

torque = 2.7–5.4 Nm. : If the bearings are used, check the static torque. If the bearings are new, check the continuous torque.

Install a dial gauge to the bar-hold and shift the cam to check the tolerance between the bevel gear teeth. The tolerance should between 0.36– 0.48 mm. To increase the gap while keeping the load on the bearing unchanged, take off shims from the crown wheel side and insert them on the opposite side. To decrease the gap, take off the shims from opposite the crown wheel and insert the on the crown wheel side.


Model

Page

T4 HiTech

8


– Differential

2.923


6.000


17.538


13/38


max 55°

Axle turning

± 7°

Caster

0°


5.5°

Camber

1°

Toe-in

mm 0-2

Flange distance

1900 mm

Differential

Valtra Axle LS

80W-90

GL-5 LS

Planetary reduction, front axle with brakes

Dana 740/561

8.5

2.7x 2


Model

Page

T4 HiTech

9

Torques and liquids

10 Nm, Loctite 270

220 Nm, Loctite 270

202 Nm

12 Nm, Loctite 243 202 Nm

200 Nm, Loctite 243


270 Nm, Loctite 270

2

2

270 Nm

3

3 Nm, Loctite 243

190 Nm

3

300 Nm

2 202 Nm

75 Nm

2

15 Nm, Loctite 243

90 Nm

1 7 Nm

4 52 Nm

GUID-CB99AB34-C521-4628-918C-DF957BDD9373

1. 2. 3. 4.


In addition to bearing cap and steering cylinder, lithium-based grease is applied to bearings, sliding parts and used to lubricate seals or parts during assembly.


Model

Page

T4 HiTech

10

Setting values Press fit of the king pin standard value (not loose)

0.7-0.8 mm

Rolling resistance for pinion shaft bearings (measured using torque meter): – Bevel pinion shaft bearings without seal ring

2–4 Nm


2.7–5.4 Nm

Tolerance between the bevel gear teeth (measured from input flange

0.36–0.48 mm

bolt hole using a dial indicator) Axial clearance (between axle housing and pivot bearing brackets)

0.1–1.1 mm

2342 1900 1636

o

5 3 3

1

5.5

o

5.5

1

2 4

55

°

M

ax

3

1

5

Ø72 x Ø38

TOE IN 0...2 mm

6

GUID-E3A36F79-33B2-4147-ACD7-A7D3F015A5D8

o


1. 2. 3. 4. 5. 6.


Model

Page

T4 HiTech

11


Model

Page

T4 HiTech

12


2

3

4

5

Model

Page

T4 HiTech

13

2

1 6

7

8

11

12 13 14 2

GUID-B5F991F1-0B1A-469F-8164-5EEF0F75C765

1. 2. 3. 4. 5. 6. 7. 8. 9.

Shim calculation Bearing Shims Pressure connection Air bleeding nipple Brake piston Return spring of the piston Brake discs Planet gear, 3 pcs

10 9


10. 11. 12. 13. 14.

Model

Page

T4 HiTech

14

Oil draining / filling plug Steering angle sensor Double U-joint shaft Automatic clearance adjusting spring Brake piston adjusting screw

King pin preload = 0.7–0.8 mm Calculate the difference between sizes “first step shim” , “measured backlash” and “preload”. Example: First step shim = 2 mm. Measured backlash = 0.5 mm. S= 2 mm - 0.5 mm - 0.8 mm = 0.7 mm


21

5 6 2 1 2 7 1 8


2

432 1

Model

Page

T4 HiTech

15


1. 2. 3. 4. 5. 6. 7. 8.


Model

Page

T4 HiTech

16


Model

Page

T4 HiTech

17

• B

1

•

D 2

3

• S

C=A±B Example: C = 1.1 - 0.1 = 1, C = 1 mm

4

5

S = C - (D) Example: S = 1 - (+0.1) = 0.9, S = 0.9 mm

6


7


9

GUID-85090993-2AB8-4A38-AE30-3757990C28F3

1. 2. 3. 4. 5. 6.



65 mm




Model

Page

T4 HiTech

18


– Differential

2.750


6.353


17.471


12/33


max 55°

Axle turning

± 7°

Caster

0°


5.5°

Camber

1°

Toe-in

mm 0-2

Flange distance

1900 mm


Dana 750/570

Valtra Axle LS

80W-90

GL-5 LS


8.5

GL-5orGL5LS

2.2x 2


Model

Page

T4 HiTech

19

Torques and liquids

10 Nm, Loctite 270

220 Nm, Loctite 270

202 Nm

12 Nm, Loctite 243

202 Nm

200 Nm, Loctite 243


270 Nm, Loctite 270

2

2

270 Nm

3

3 Nm, Loctite 243

190 Nm

3

300 Nm

2 202 Nm

2

1 90 Nm

4 75 Nm


1. 2. 3. 4.



0.7-0.8 mm


2–4 Nm



2.7–5.5 Nm


0.40–0.51 mm


0.1–1.1 mm

Model

Page

T4 HiTech

20

2240 1900 1636

o

5 3 3

1

5.5

o

5.5

1

2 4

55

°

M ax

3

1

5

Ø72 x Ø38

TOE IN 0...2 mm

6

GUID-904BE7DC-E53C-4AD8-849C-65FBFEC7167A

1. 2. 3. 4. 5. 6.


o


2

1

Model

Page

T4 HiTech

21

3

4

5

6

3

3

GUID-6E81042B-AE9E-4F53-98C3-94063BDE9337

1. 2. 3. 4. 5. 6. 7.



7



21

5 6 2 1 2 7 1 8


2

432 1

Model

Page

T4 HiTech

22


1. 2. 3. 4. 5. 6. 7. 8.


Model

Page

T4 HiTech

23


Model

Page

T4 HiTech

24

• B

1

•

D 2

3

• S

C=A±B Example: C = 1.1 - 0.1 = 1, C = 1 mm

4

5

S = C - (D) Example: S = 1 - (+0.1) = 0.9, S = 0.9 mm

6


7


9

GUID-85090993-2AB8-4A38-AE30-3757990C28F3

1. 2. 3. 4. 5. 6.



65 mm




Model

Page

T4 HiTech

25


– Differential

2.750


6.353


17.471


12/33


max 55°

Axle turning

± 7°

Caster

0°


5.5°

Camber

1°

Toe-in

mm 0-2

Flange distance

1900 mm


Dana 755/509

Valtra Axle LS

80W-90

GL-5 LS


8.5

GL-5orGL5LS

2.2x 2


Model

Page

T4 HiTech

26

Torques and liquids

10 Nm, Loctite 270

220 Nm, Loctite 270

202 Nm

12 Nm, Loctite 243

202 Nm

200 Nm, Loctite 243


270 Nm, Loctite 270

2

2

270 Nm

3

3 Nm, Loctite 243

190 Nm

3

300 Nm

2 202 Nm

2

1 90 Nm

4 75 Nm


1. 2. 3. 4.



0.7-0.8 mm


2–4 Nm



2.7–5.5 Nm


0.40–0.51 mm


0.1–1.1 mm

Model

Page

T4 HiTech

27

2240 1900 1636

o

5 3 3

1

5.5

o

5.5

1

2 4

55

°

M ax

3

1

5

Ø72 x Ø38

TOE IN 0...2 mm

6

GUID-A3673821-E8D0-4F08-9932-13F54DBD518B

1. 2. 3. 4. 5. 6.


o


2

1

Model

Page

T4 HiTech

28

3

4

5

6

3

3

GUID-6E81042B-AE9E-4F53-98C3-94063BDE9337

1. 2. 3. 4. 5. 6. 7.



7



21

5 6 2 1 2 7 1 8


2

432 1

Model

Page

T4 HiTech

29


1. 2. 3. 4. 5. 6. 7. 8.


Model

Page

T4 HiTech

30


Model

Page

T4 HiTech

31

• B

1

•

D 2

3

• S

C=A±B Example: C = 1.1 - 0.1 = 1, C = 1 mm

4

5

S = C - (D) Example: S = 1 - (+0.1) = 0.9, S = 0.9 mm

6


7


9

GUID-85090993-2AB8-4A38-AE30-3757990C28F3

1. 2. 3. 4. 5. 6.



65 mm




Model

Page

T4 HiTech

32


– Differential

2.750


6.353


17.471


12/33


max 55°

Axle turning

± 7°

Caster

0°


5.5°

Camber

1°

Toe-in

mm 0-2

Flange distance

1900 mm

Differential

Valtra Axle LS

80W-90

GL-5 LS

Planetary reduction, front axle with brakes

Dana 755/510

8.5

2.8x 2


Model

Page

T4 HiTech

33

Torques and liquids

10 Nm, Loctite 270

220 Nm, Loctite 270

202 Nm

12 Nm, Loctite 243 202 Nm

200 Nm, Loctite 243


270 Nm, Loctite 270

2

2

270 Nm

3

3 Nm, Loctite 243

190 Nm

3

300 Nm

2 202 Nm

75 Nm

2

15 Nm, Loctite 243

90 Nm

1 7 Nm

4 52 Nm

GUID-CB99AB34-C521-4628-918C-DF957BDD9373

1. 2. 3. 4.


In addition to bearing cap and steering cylinder, lithium-based grease is applied to bearings, sliding parts and used to lubricate seals or parts during assembly.


Model

Page

T4 HiTech

34

Setting values Press fit of the king pin standard value (not loose)

0.7-0.8 mm

Rolling resistance for pinion shaft bearings (measured using torque meter): – Bevel pinion shaft bearings without seal ring

2–4 Nm


2.7–5.5 Nm

Tolerance between the bevel gear teeth (measured from input flange

0.40–0.51 mm

bolt hole using a dial indicator) Axial clearance (between axle housing and pivot bearing brackets)

0.1–1.1 mm

2364 1900 1636

o

5 3 3

1

5.5

o

5.5

1

2 4

55 °

M

ax

3

1

5

Ø72 x Ø38

TOE IN 0...2 mm

6

GUID-27F4C61C-0FAA-42A7-B252-71C90BDC9690

1. 2. 3. 4. 5. 6.


o


Model

Page

T4 HiTech

35


2

3

4

5

Model

Page

T4 HiTech

36

2

1 6

7

8

11

12 13 14 2

GUID-B5F991F1-0B1A-469F-8164-5EEF0F75C765

1. 2. 3. 4. 5. 6. 7. 8. 9.

Shim calculation Bearing Shims Pressure connection Air bleeding nipple Brake piston Return spring of the piston Brake discs Planet gear, 4 pcs

10 9


10. 11. 12. 13. 14.

Model

Page

T4 HiTech

37

Oil draining / filling plug Steering angle sensor Double U-joint shaft Automatic clearance adjusting spring Brake piston adjusting screw

King pin preload = 0.7–0.8 mm Calculate the difference between sizes “first step shim” , “measured backlash” and “preload”. Example: First step shim = 2 mm. Measured backlash = 0.5 mm. S= 2 mm - 0.5 mm - 0.8 mm = 0.7 mm


21

5 6 2 1 2 7 1 8


2

432 1

Model

Page

T4 HiTech

38


1. 2. 3. 4. 5. 6. 7. 8.


Model

Page

T4 HiTech

39


Model

Page

T4 HiTech

40

• B

1

•

D 2

3

• S

C=A±B Example: C = 1.1 - 0.1 = 1, C = 1 mm

4

5

S = C - (D) Example: S = 1 - (+0.1) = 0.9, S = 0.9 mm

6


7


9

GUID-85090993-2AB8-4A38-AE30-3757990C28F3

1. 2. 3. 4. 5. 6.



65 mm



Powered front axle 13.3.2015

Model

Page

T4 HiTech

1

T1 Ø147,8 1,5x45°

M16

0 1

4 2 4 1

16°

Ø141 GUID-CF6449A7-EF6E-494E-986D-C9B0C29CB823

T2 M16

0 1

4 1

Ø124 Ø155,8 GUID-782F17D5-6614-4FFA-883E-BA80F223BB04


Model

Page

T4 HiTech

2

T3 262 247 40

82 14

2x45°

20 30°

68 Ø8H8+0.022 0

0 6 . -0 0 3 0 . -0

7 H 4 4 Ø

0 4 Ø

6 /n 7 H

0 2 Ø

0 2 Ø

0.5x45° 1x45°

1x45°

25 40

GUID-56AC18AF-BD4A-4F46-8B19-02616C4625EA

8 .0 0 4 .0 0 5 6 Ø

R5 0 1

42 14 GUID-878BCDD8-59A6-4EE4-A390-0DD4EF5B67F7

68

13

5 3 Ø

0 4 Ø

5 6 Ø


Model

Page

T4 HiTech

3

T4

107

8 .0 0 -

5 2 Ø

5 2 Ø

R

5

10x15° 0.5-0.2 50 PROTECT FROM CARBURIZING

294

109.5 418.5

GUID-3B054169-EBE8-4A23-9748-090F511DBF2E

75

2 .1 0 -

0 4 Ø

2 . 0 +

0

5 . 4

4 Ø

4 6 Ø

4 7 Ø


T5 17 5 2 1

100

1 2 5

50

R 1

4 2 Ø

5 5

9 1

1

0

R 10 0 R1

0 9 3

5 3 3

° 5 4 x 5

GUID-D4AF40A2-ADCE-4E85-98C3-3B8EE8DF6469

Model

Page

T4 HiTech

4


Model

Page

T4 HiTech

5

T6 230

5x45

X detail

A

A 2 3 1

0 6 1

54 4 7

0 4

°

4

,5 12

5

X detail

A-A 195 45 0 1

5 1

6,5

1 0, ø7 2x45°

2 0

2 ,3

185 ø8 0

1 0

3 0

5

GUID-F74AA1CA-4402-4330-ADAE-66A2A5687E0E


Model

Page

T4 HiTech

6

T7

Ø30

Ø30

Ø20

Ø20

0 3

0 3

5 5

4 5

5

5

0 2

9 1

21°

12°

Ø79

Ø94,5

Ø88,7

Ø111

GUID-870E3EDB-6707-4203-8F1D-BD56C9B9FA14

T8 Ø60 M16

0 4 5 6 5 4

5 1 0 1

Ø35 Ø60 Ø89,8 GUID-CAF2A96C-827F-4DEF-8185-94CECF19DF4E


Model

Page

T4 HiTech

7

T9 20 3

1x45°

10

ø 3 0

M 2 2 x 1 .5

1 3 0

100

6

10 GUID-D25555F1-7DBA-4917-9339-F68278CC4C94

T10

Ø72 M16

1,5x45°

5 1

9 , 2 3

° 5 4 x 5 , 0

2 , 9

Ø35 Ø60,8 Ø72 GUID-AA652088-255C-4301-99B3-A71CF63F9A76

1 5 0


Model

Page

T4 HiTech

1

19 18 17 16 15

13

7

6 5

6 28 14

4

27

2

26

1 11 23

22

12

21

3 10 9 30 29

25 24 20

8 GUID-1A0DC4EA-9AD3-4E1F-83FD-60AB68148943


Model

Page

T4 HiTech

2

7

GUID-81ED5657-8DE3-42E6-81DB-36B74CE500D3

1

Snap ring

GUID-BAF62B11-3CD6-42A1-B671-B2127AC1360A

Drain plug

6

5

3 6

GUID-6E90B84D-7AFD-437E-8283-9D896EECBA25

Planetary gear Bearing

GUID-FD277F80-AEC7-4F65-80BA-CD7FEF237765

Screw

16

GUID-34412516-72F4-4D84-8C4E-A5769E1A1DE8

O-ring 4 GUID-2FD8FDD3-82DB-4727-92A4-8F391D6574DB

Planetary cover


Model

Page

T4 HiTech

3

22

21

20 GUID-93874D83-7617-4673-A03F-E6B49A51BFED

GUID-6D0ADF46-EAAA-4579-BCD0-BBAA07A365CF

Snap ring

Screw Reversal spring NOTE: If the springs are weak or deformed they must be replaced.

29

8

9

8

GUID-B55680E7-5AB2-478C-860A-C626219C2E90

Braking disc Braking disc

GUID-8CFE7BF6-F8CA-4F45-BC3B-0BF8C71BFF0F

Adjusting screw NOTE: If disks are not to be replaced, avoid changing their position.

23 GUID-1FF003D2-73CF-4484-BCED-46A63509ED89

Piston


Model

Page

T4 HiTech

4

12

30

GUID-6A99F7CE-948F-4A29-9EF9-A9CCBDB4DE9A

Regulation spring

GUID-2EE6234C-D58D-4273-A455-CB0AE8F4B79C

Screw

23

26 27

GUID-7E6D8494-DFDA-493C-A97E-CB5A6BDCEBB9

Piston

GUID-95A4F1D6-00BD-474A-B881-3BDE61288D13

O-ring O-ring NOTE: The o-rings must be replaced each time the unit is disassembled.

11 GUID-D50302E8-B485-4E27-8A7E-190F51C53E78

Crown flange


Model

Page

T4 HiTech

5

17

14

GUID-3B373884-3A3E-4664-81E7-04354DE4F750

Snap ring

GUID-B717F4E8-0D23-4858-A0D2-E8B59C3C84CE

Hub

11

13

15 GUID-7F5332C5-8C40-4B9F-90DA-280D0B7E4E4C

Crown flange

GUID-523883EB-1D7F-4CE0-B60B-D22881CFA6EA

Bearing

28

17

GUID-F92297A3-5084-4BAA-AB04-82769463645C

O-ring

GUID-E2C8259C-745F-4663-B31C-D0E40F088415

Hub


Model

Page

T4 HiTech

6

19

T1

18

15

T1

GUID-59882AC9-D687-43F4-8A23-92F77D424399

Sealing ring GUID-5CD24DCF-9887-4FBD-A500-CEF3A6AD583C

Special tool Thrust block

18

Thrust block

18 GUID-040DCC15-4362-4AEC-835A-38D0A7256321

Internal bearing

GUID-8414DCD1-BB65-4F43-98D8-CED93731E88D

Bearing NOTE: Move the bearing to the limit stop by hammering lightly all around the edge. If insertion is difficult, use a punch with a suitable diameter to seat it.

18

15

GUID-D5F7539E-E404-45D2-9362-7F32FB633FB5

Thrust block Thrust block NOTE: Avoid damaging or deforming of the thrust blocks.


19

Model

Page

T4 HiTech

7

T2

15 GUID-8A9AF640-C286-4717-A160-966DE0365C00

Inner bearing GUID-DB3F80AD-FFC0-4859-BD16-7955B21833AD

Special tool Sealing ring

NOTE: Using a plastic hammer, drive the bearing to the limit stop by lightly hammering around the edge.

NOTE: Ensure the ring is correctly oriented. The flat surface should be visible after mounting.

28

17

GUID-DF0995A2-08D5-4500-B3D4-DD4554BEED51

O-ring GUID-FF5EC282-46B6-4DC0-9512-504F5D368747

Hub

13

GUID-59125A5E-2C33-443A-AD08-AD448DDDE7DF

Crown flange Crown wheel

11


Model

Page

T4 HiTech

8

Drylock

68 - 75 N·m 12

14

GUID-8B642912-457B-446A-ADC8-1431A291AE76

Snap ring

GUID-C488D437-63CF-45AF-9446-E06F059A6601

Screw

23

26 27

11

GUID-2DFDF545-5ED2-47DB-BA79-D8752A09CACC

Piston GUID-9F6D4E24-C1B8-404A-BF22-08E23CB8B4A1

Crown flange

O-ring O-ring

NOTE: Match up the punch marks on the joint case and the crown wheel carrier flange.

30

GUID-185F3569-38A8-4158-9521-9DC7B6BA1629

Regulation spring


Model

Page

T4 HiTech

9

Loctite 243 10 - 15 N·m

22

23

21

GUID-35CA52F5-BF75-4CDF-A3B3-F0ED54BA1455

Piston

GUID-214ACB1D-4BD9-40CC-8419-2A648CBF9575

Screw NOTE: Lightly hammer all around the edge in an alternate sequence.

Reversal spring

Drylock

5 - 7 N·m

29

8

8

9

GUID-D90A5689-8893-49BA-BB5C-634E3C376CF4

Adjusting screw

GUID-06074031-CCB9-472A-9915-89A427B78082

Brake disc Brake disc NOTE: The first brake disc to be inserted must be of steel material. The second brake disc to be inserted must be of friction material.


Model

Page

T4 HiTech

10

7

GUID-97D4A806-C061-4705-9466-C39B09B3D554 GUID-4A506BA0-CD3B-4938-B9A2-1B7AB212EC7E

Snap ring

16

20 GUID-CE6BCBC1-2EAB-495C-B628-F69EC075D8B0

Snap ring GUID-4D06DB91-6C4D-4568-8FDB-2C88EDAD0371

O-ring NOTE: In order to hold the o-ring in position, apply grease to it.

5

6

GUID-F3A05AFD-7F17-450C-A65D-CCF727301CF9

Planetary gear Bearing

6


32 - 53 N·m

3

4 GUID-FDEDF03A-F525-4C8D-9B16-F2B3FBE1E4B1

Screw Planetary carrier cover

1

90 N·m GUID-3C2413BE-8F00-49C4-B7A2-DE6078600771

Oil fill plug

Model

Page

T4 HiTech

11


Model

Page

T4 HiTech

12

Electronic Sensor

31 30 26

27

29

28

6

Electronic Sensor

4

7 6

5 8

7 9

8 10

32

9 13

25

10

11

24

12 14 23

22 21 20 19

18 17

16 15 GUID-5918AFF8-6F4A-42E7-8729-3F0FD6980B2A


Model

Page

T4 HiTech

13

5

4

GUID-84124CF8-15D1-42BC-8DC6-20F73796E3B6

Rubber joint Sensor pin GUID-E4CF73C2-8628-4184-ADF4-17F0574C0971

6

GUID-ADDA1D9B-1EBA-477F-8CAC-05C29200D009 GUID-FD2853E4-3A94-4656-81E4-AC6F1DBABE3E

Capscrew NOTE: Screws cannot be re-used.

7 8

8

GUID-9DF116FA-5B7F-4631-806A-45AFC54586D1

GUID-B30D62AB-EB1C-4986-B9B7-02B8791DA8CC

Upper knuckle post Shim


Model

Page

T4 HiTech

14

15

16

GUID-243E5A8F-86B0-4014-992C-92907A14EBA0 GUID-85B33D00-0BED-4AE0-9BA5-58C05373661B

Cabscrew Knuckle post NOTE: Screws cannot be re-used. 20

10 18

19

9 17

GUID-912D5A6D-4AEE-4B50-9D2B-2929AFA734BA

Snap ring Shim GUID-7F86B979-1E13-460E-B59A-C45EC964A290

Sealing ring Bearing Sealing ring Bearing

32

GUID-C96C7A3D-C4CF-41D2-9FE7-C10D13F4C246

U-joint


Model

Page

T4 HiTech

15

26 23

GUID-53595734-7DB0-4B2B-A880-FB66CC694BA4

GUID-6BD78DB2-026C-4994-812D-F6CC45CC563B

Fastening screw

Sealing ring

22 GUID-D8A0806F-3290-4E5D-B190-3672901CE597

Snap ring GUID-751424CC-7000-495C-B522-B6E1B9A5DAF3

21

28

GUID-09CF48E4-E1DF-47EF-BD48-7B09B03DB279 GUID-E0CEB02E-DABA-4D33-8121-C98B87C746B9

Bearing

O-ring


Model

Page

T4 HiTech

16

13

29

GUID-BFE54027-9B86-48FC-88D0-436F1F45270A

O-ring

GUID-27DC1E40-32AE-4322-9F6D-25F8D9EF26DC

Snap ring

30

12

14

GUID-ABECCECF-F9ED-4BE6-B855-896A7D6C08BA

O-ring

GUID-84AA4F03-D3BD-49B4-9940-C6E59C7B482E

Fastening screw Steering sensor

11

10 GUID-2C35DAFD-1980-4A2F-A220-40AE52D3680E

Steering sensor guard GUID-51243723-E852-4E3A-A795-C7257130125E

Thrust block Thrust block

18


Model

Page

T4 HiTech

17

10 24

18

GUID-7B4276D1-34BD-4F9A-BF7A-47DFD3B03185

Seal ring NOTE: Write down the direction of assembly of seal ring.

GUID-75C495AB-68D3-43ED-8EEB-D3DDBBB645AE

Thrust block Thrust block NOTE: Verify thrust blocks are installed at end of stroke.

25

A GUID-C7257474-73D5-4883-A977-3B8B519210A7

Bushing NOTE: Note the direction of assembly for the bushing.

GUID-1FC9B20F-1D3F-488C-A8AA-CADA2BEEBD6A

Slot


Model

Page

T4 HiTech

18

30

12

14 GUID-0CE2FD94-A854-48D4-8A19-C60AE4B60E60

Loctite 243

O-ring

2,5 - 3 N·m GUID-96930402-0EA1-481E-AA70-7001A5224737

Screw Sensor

13 29

GUID-47632211-4BE9-4D8C-8889-C9C45DDED70F

Snap ring GUID-0DB122D1-A48B-4254-A6DE-19D23DE10CFD

O-ring

NOTE: Make sure the ring is properly set in its seat.

11

28

GUID-6A9F3C31-B115-4A65-8801-5E0EC748CBE9 GUID-40916946-27B1-4EFC-92D5-91AA15B539D5

Steering sensor guard

O-ring


Model

Page

T4 HiTech

19

24

T4

GUID-12DF8A9D-2789-4B15-9E10-7051028B17D1

NOTE: Ensure the harness is locked in position.

GUID-8629F2F3-3E2F-4C46-B84C-0EBCA211081F

Sealing ring Special tool

21

26 Loctite 243 8 - 10 N·m GUID-CD663C32-79C6-4660-A8BF-C85C8683C215

Screw

GUID-CC3B1004-4714-49C9-A963-ED6A2266760B

Bearing

25

T3 22 GUID-DFB55566-E95B-4C33-B653-F345AA463E8B

Bushing Special tool

GUID-A4316115-1482-4BA6-8B8E-F556DB78E048

Snap ring


Model

Page

T4 HiTech

20

23

GUID-CFEA3974-5705-4035-A2D1-5CCD2B2EC25D

Sealing ring GUID-E9D16BE9-EBC5-452B-A882-ACB681A37F5A

32

GUID-D40F426D-E914-4DB4-9A6C-831F3CB796BC

9 17

U-joint m m ,5 0

GUID-289E24FF-1647-44C4-9F53-C2070A50CF37

Sealing ring 20

Sealing ring

19

GUID-16270472-B591-43D9-99C0-65E0E37FEB89

Snap ring Shim


Model

Page

T4 HiTech

21

10 18

15 GUID-BAF0C540-31CD-41BC-9F47-EAA723E362FA

Bearing 182 - 202 N·m

Bearing

GUID-2585AAB9-E0A1-43F4-BF2D-123C3CFFF3EE

Capscrew

8

16

GUID-40F2CE94-E498-4ACB-928A-27B0479CC473

Shim GUID-A5F596DD-6FD6-43CC-B8EF-EE2FB2679461

182 - 202 N·m

6

GUID-7BABE9C4-6F7C-4180-BC5F-F9E91436F201

Capscrew


Model

Page

T4 HiTech

22

8

GUID-A30CCEC2-F4B1-49F0-A405-F7C2242359A8

GUID-57968DB1-31C5-4D42-BDC6-41807F13E55F

Shim First step Shim = 2,5 mm Measured Backlash = 1 mm S = 2,5 mm - 1 mm - 0,6 mm = 0,9 mm.

GUID-D1B56E60-E108-4F89-803F-225E83635AEB

7

6

GUID-02686CF1-FC09-4AD0-8F15-7C0B905A212A

Thrust block GUID-EF88A3DF-755A-43DE-BED6-14CEAAF70F32

Capscrew


Model

Page

T4 HiTech

23

182 - 202 N·m

6

GUID-CAA4082D-2F9B-4694-B72C-DCEFEEF1EB7F

GUID-F7F5904E-0A74-49D2-B5C1-C2F28FFA583F

Capscrew

5

4

Loctite 243 10 - 12 N·m GUID-F3B7BFC1-0101-483F-996B-E84FE2504535

Screw Sensor pin

170 - 190 N·m

GUID-3B9ADE89-41A5-4A47-88FC-F49BD55B58BE


Model

Page

T4 HiTech

24

7 6 8

5

4

9

10

2 11 12

3

18 15 14

17 15

16

16

13

16

20

17

19 18

GUID-19529826-9724-4407-B034-E0BE08C4E016

13

14

1 20

16

19


Model

Page

T4 HiTech

25

3

1 GUID-5AFA3D7C-E1D0-45C8-AD54-1549590409CA

Tie rod GUID-85CACB86-186F-44E1-90CC-C5456E811761

Tie rod nut

6

GUID-7F6C72EA-5561-4F76-85FD-386FFFC5882E

Nut GUID-9660BF9D-8856-4966-A034-EDBBC59CD409

10 3 GUID-A28320B9-2301-4208-9B98-3B6CDA8D3C58 GUID-5D0333B1-0057-46D7-B03B-CA983A79A2D3

Tie rod

Snap ring Snap ring

12


Model

Page

T4 HiTech

26

11 4

GUID-D5432300-D2C9-47C3-8F00-9279EF24D5CE

Joint boot

GUID-CFB15A72-5BB1-44C7-B08F-6F8737406A38

Securing screw

7

2

GUID-0E3899CC-4C28-47EA-B1A3-383D4E68BF7E

Snap ring

GUID-8B942A96-8C40-409E-9089-026C769F9105

Cylinder

8

GUID-16D96974-CAC5-4ADB-9A64-8480233BABA6

Joint boot

GUID-4A613F59-EEE4-4621-99B8-8D9257AE1C75


GUID-8C9A275F-98D6-43A5-90D0-A15800890D03

Model

Page

T4 HiTech

27

GUID-E8848179-D9CB-4DB0-BA6E-AE80B1CBF26E

NOTE: Insert the cylinder head so it is flush with the cylinder.

GUID-325E55E8-FDDF-4F47-90AC-D881047307C8

GUID-39297BB2-AD88-49B5-9FBE-B9DEE4879CBB

GUID-5957990B-6BF4-4294-B3BD-3D86027914FA

GUID-BF7997E1-C1D5-49DA-9651-E9F11A6D6197


Model

Page

T4 HiTech

28

13

18

GUID-2688FC8B-1BE6-432F-9029-82B4A25193CF GUID-21554976-62A1-478D-9288-9653ACF276C6

15

15

GUID-D5253321-1E70-426D-B0CE-E07346A8A5B3

NOTE: All seals must be replaced every time the unit is disassembled. Particular attention must be paid not to damage the seats of both seals and piston slide.

19

19 GUID-9AB94E80-314C-4847-B574-40E53F12DC93

20

20

GUID-A8190668-DA02-40C4-AE00-915958FE54ED

In order to facilitate assembly, apply grease to the outer surface of the piston. Do not roll the seal up. Thoroughly check that positioning of the backup ring is correct.


16

16

Model

Page

T4 HiTech

29

17

14

GUID-0516A70C-7554-462C-AD8D-E4AFD13CC71A

o-ring Guide ring

GUID-265B65E1-77BF-42C8-AFC1-343DDEB1CBD1

NOTE: Insert the head to line it up with the edge of the cylinder.

Seal In order to facilitate assembly, apply grease.

GUID-FC6250A2-2065-46CC-87F8-8A4F11CF1337

GUID-DAACC0BD-93E7-4807-B89D-006B4188109B

NOTE: Apply a little grease to seals and cylinder.

GUID-F37C9A44-D5E5-4EE4-AA51-A57B258FB823


GUID-835F050B-6CB8-416A-AA73-2D4611D35D02

Model

Page

T4 HiTech

30

GUID-C73B98BB-83D3-47F3-A658-A5C48CCAC226

2

GUID-CB7AA1BF-ABBF-4872-B6D8-3285703FB5D6 GUID-B9E3BFF1-DDE0-44BC-AFC1-1677F68ABA73

Steering cylinder

Loctite 270 200 - 220 N·m 4

GUID-9DC9F76D-4936-4A58-9947-DEF62D0F2437

GUID-B0B0D755-E2AE-4C3D-9056-CE673D4A9DBA

Cylinder screw


Model

Page

T4 HiTech

31

8

12

GUID-C226BA7F-ECB9-476C-B29F-5AFB5391A969

10

GUID-CB39DC0B-ED42-4CF6-8D39-B1480EC63488

Joint boot

Axial joint tie rod boot snap ring Axial joint tie rod boot snap ring

3

3

7 GUID-8A030011-A395-4304-B607-61CE8E03FABC

Snap ring

Loctite 270 240 - 270 N·m

Loctite 270 240 - 270 N·m

GUID-66AD4CEE-73AA-46AC-BACB-8B4BB1419495

Tie rod

170 - 190 N·m

11

GUID-3C809BBA-91F0-411F-961F-83AC0934BC32

Joint protective boot 1

GUID-4E441E25-C45E-4A11-886B-F9800B956067

Lock nut


Model

Page

T4 HiTech

32

6 GUID-E6A0C1B5-A586-445E-AC6E-716FF28FFE92

240 - 270 N·m GUID-A0B4AC35-2D5E-40F2-9F39-5A0F4592B37A

NOTE: Adjust by the same amount on each steering rod.

T5

GUID-530B017A-81D8-4E27-9578-1124CF0605B1

Special tool

GUID-60BCF7AA-B82E-4C8F-9A0B-1BC2801ED69E

GUID-06A3199B-41C4-4796-A1B4-59A0A66772F8

NOTE: In order to check the rear distance, rotate the bevel pinion and check tools are flat.


1

Model

Page

T4 HiTech

33

2 3

7

8

9 4

12

13

10

5

11

12 14

6 15

13

10

16 17

12 13

29

24

19 21

25 23 26

20 22

GUID-D7F7FF9B-D681-4601-9D17-38FADF5BA42D

18


Model

Page

T4 HiTech

34

2

GUID-AB3CC738-EA4A-4592-9BC5-02DC91732DC3

Arm GUID-2EC74A5A-8F7F-42D1-A40B-3D46363D62F0

3

GUID-E4ABF3F2-6E60-4B15-A8E9-F27B63DA87A9 GUID-B6B99CB7-2110-4D21-BDCB-D1386908B5BF

O-ring

2

1

4 5

GUID-B1608E38-C98C-4AFB-8B3F-8421FCFCB5D2

Screw Arm

GUID-7F6C1AFB-D309-43BE-8889-F1D0B9F08AB3

Shim Bearing


Model

Page

T4 HiTech

35

21

4 GUID-765FA0E0-397A-42FB-99C1-17B9FFB4424D

GUID-89DB41A7-4DC4-40AB-ACE2-E10EB0DB0464

Shim

Snap ring

Example: 0.6 mm

19 29

GUID-560DC473-EC74-49B7-B158-B1F648659776

GUID-B2B56299-30A8-49D4-A8D3-49D7C837544E

Hydraulic block disc Hydraulic block disc

5 17

7

8

GUID-208FB4EC-8D1C-4ACA-93C1-2EE6A70F5B10

Bearing Bearing GUID-67F06047-18DF-4917-9160-F5AE46040016

Capscrew Capscrew


Model

Page

T4 HiTech

36

10

11 6

GUID-9EC53995-0AE1-4D43-8F23-1B42C54B51D9

GUID-BF43AAEB-C9F4-49AD-91AB-D2D68D1838C4

Shim washer

Crown

Planetary gear

12 14

13 GUID-24BCD465-71DE-4887-AFC6-13342B67253E

GUID-3FCA0CB3-5D1D-40E5-A50E-AC1540A9415D

Spherical shoulder washer Planetary gear Shaft

9

16 GUID-B17249A0-7A82-47F6-8AC0-0E9039E73CF3

Half box Half box


Model

Page

T4 HiTech

37

23

15

10

GUID-038FA7E3-9869-4588-8246-AA0331B336A3

GUID-6F3C74D6-0511-4C00-9BA4-31525AC71A03

Shim washer

Snap ring

Planetary gear

17

18 GUID-37FACC1F-48BA-45D8-A4D5-D19BFDC96D56

GUID-4ED33490-DBA5-4EAB-8535-DBD2708A6403

Thrust block Shim 24

18

GUID-CEB260CF-C77F-4DA5-A5CD-F51816A4D574

Piston

GUID-DD0E8040-DF05-4A39-9AA9-9FE3435AC82F

Shim Example: 1.2 mm


Model

Page

T4 HiTech

38

20 24

22 25

26

GUID-AFEFB1F6-CC8B-49E8-97F1-68DB0AD6475B

Flange Bearing

GUID-AE55C28F-07DF-4385-B16A-02DE88862E2D

Seal

Piston

Seal

25

26 20

GUID-FE026899-0322-40CA-B321-090A18C17547

Seal Seal NOTE: All seals must be replaced every time the unit is disassembled. Particular attention must be paid not to damage the seats of both seals and piston slide.

GUID-7599B1F2-2B51-4AF0-924B-6E690EB6A849

Flange


24

Model

Page

T4 HiTech

39

18

GUID-F0154C8C-92D4-44EF-BC23-C7044DB6DCD0

Piston

GUID-B829D0AA-14D9-448D-BDAE-B863EE059141

Shim Example: 0.6 mm

17

18

GUID-BBFDAE20-2E77-49CA-BF30-9EBA9195F42E

Piston GUID-3EAB3616-D5AE-4EFE-B85B-BD395197D8AB

Thrust block Shim 23

GUID-DA6D11A6-9BEE-4BA2-B99C-A341C7C2640E

Snap ring NOTE: Ensure the ring is properly set in its seat.

NOTE: Verify the thrust block is installed at end of stroke.


Model

Page

T4 HiTech

40

10

15 11 10

GUID-68BB4CE5-60C1-4C60-95FE-ABD2923DDC0D

GUID-140F4A1B-36A1-4B20-941C-82F88E6659D4

Shim washer

Shim washer

Planetary gear

Planetary gear

12 14 9

16 13 GUID-D4F694BF-271B-413E-8FA6-D7810E23533C

Half box GUID-383AF009-C552-445C-8B51-FDA4E9BDBC6E

Spherical shoulder washer Satelite gear Shaft

Half box The match marks on the two half-boxes must correspond.


Model

Page

T4 HiTech

41

19

6

GUID-27401724-3313-493C-A318-B9D68F8C7CFF

GUID-02343DB9-EB73-4F0F-B9DD-C16229684FAB

Crown wheel

Intermediate plate First and last disc must be made of steel material.

If the crown has been replaced, reinstate clearances.

19 29

7

29

8

GUID-C373BF28-CBEC-4424-B9A9-3BF7F979B7E5

Differential lock disc Loctite 270 110 - 130 N·m

Differential lock disc

GUID-A36EE6D1-78DF-4E24-BB28-EE2D76B38771

Screw Screw 21

Use only new screws pre-treated with locking adhesive using the criss-cross method.

GUID-2F6B1838-D2EA-45DB-81E0-C8B0039CBAFF

Snap ring


17

Model

Page

T4 HiTech

42

5

3

GUID-34C4DC26-6207-4088-B84E-8D0B8A182445

Bearing

GUID-C605D5D8-66E7-48F7-886E-CDE91896909F

O-ring

Bearing NOTE: Once the bearing has cooled down, lightly lubricate bearing with SAE85W90 oil.

4 GUID-C422FDFE-0728-457E-AB3C-97AC5B34556E

Shim GUID-C5D16C7C-1B68-467F-8F91-194A297CB788

Example: 1.2 mm NOTE: For the correct bearing preload, use the srcinal shims pack distance.

GUID-57E3DC7A-547C-4FA3-A56E-5763DC8CFE01


Model

Page

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43

5 4 GUID-BBF678FD-7CC9-446C-BEA4-CBF5768B8E52

Shim Thrust block GUID-472C7464-FD13-4012-89F2-62CD33B08DF8

NOTE: Verify thrust block is installet at end of stroke.

Example for 755/509: Pinion rolling torque: 2 - 3 N·m. Pinion+differential rolling torque: 2,7 - 5,5 N·m.

Loctite 243 200 N·m

If torque exceeds the maximum value, then the size of shims of differential unit needs to be reduced. If torque does not reach the minimum value, then the size of shims of differential unit needs to be increased. If bearings are not new, check the static torque; if bearings are new, check the continuous torque.

2 1

GUID-BB5E8FD4-D1C6-4FB0-8AA7-614DE62ED9CF

Screw Arm


T9

In order to increase the gap while keeping the load on the bearing unchanged, remove shims from the crown wheel side and insert them on the opposite side. In order to decrease the gap, act the other way round.

740/560 740/561 750/570

0,36 - 0,48 mm

755/509 755/510

0,40 - 0,51 mm

GUID-1EF316F6-8094-4D73-B6AC-53E8B911D9FE

Page

T4 HiTech

44

mm 65

GUID-FFF83261-26A4-4FE0-BF41-B4C617BA66FC

Tolerance:

Model

GUID-96677D21-1005-4E8B-9E6F-E342DAA86D15


Model

Page

T4 HiTech

45

1

2

3

14

13 12 9 8 10 7 6 5 4

GUID-2F2C6442-FF15-4454-AD26-65960D46374D

11


Model

Page

T4 HiTech

46

T6

1

4 GUID-34FF54B6-3ADD-4AD9-AFE5-10CE8A1137D3

Special tool Nut GUID-F02FF155-9C32-45CB-8A1B-4343337F3441

Arm

NOTE: If disassembly is difficult, heat the nut to approximately 80°C.

2

5

4

GUID-D26D6753-CE50-4666-AD42-188457166BA7 GUID-816536EC-AC8D-4E3A-B674-A93FB78EBDE2

Differential unit

Nut Washer

7 GUID-6F6B4874-6108-44C7-8939-327528029852

Flange


Model

Page

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47

14

7

10

GUID-DC0BE523-5A7D-47CD-9850-0194377822F7

GUID-3FC2FB6B-5252-401D-B235-696C66E56297

Pinion

Flange O-ring

14 13

8 GUID-575E235F-FAFC-4618-8683-17FDA13FFFEE GUID-EC67F419-A198-4331-B69A-EC3957323401

Inner bearing

Seal ring

Pinion

9

11 GUID-5D3DB138-135A-4D47-A5BD-23A571B2F3B4

Snap ring

GUID-81C9C38A-AA1E-49BB-B420-9B93CEB7F2E3

Bearing


Model

Page

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48

12 13

11 11 GUID-A2A320A5-D774-4118-92CB-1A3F8F53A921 GUID-0A6F5453-D05A-4D33-AEA3-6D8B8CAB0D6A

Thrust block

Shim washer Thrust block Example: A = 1,1 mm.

12

OLD PINION

13

GUID-89085C18-F0BE-4852-BD56-9CF7EAB1FFFB

Shim washer Thrust block GUID-97E6638A-289E-4600-91EA-D1692C9507CA

C = 1,1 - 0,1 = 1 mm C = 1 mm.


Model

Page

T4 HiTech

49

T7

NEW PINION

11

13 T7 GUID-C0890704-C73C-4F2D-8B50-1572F93BB67E

Special tool GUID-8C906F5F-A1F5-4C9E-A3AC-72E94DF49232

Thrust block

S = 1 - (+0,1) = 0,9 mm S = 0,9 mm.

Inner bearing

12

13

GUID-DDACA0AF-A9CB-4126-BAE4-B5B75730A16E

Shim Thrust block NOTE: The thinner shims must be placed in between the thicker ones.

GUID-9321710C-371D-491F-9A00-CE3494EDD930

NOTE: Before starting the next stage, ensure that the thrust blocks have been completely inserted into the seat.


Model

Page

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50

11 GUID-CAAA4657-939A-4B14-B039-8010DB254DCE

GUID-511DC848-935B-4C90-9A36-99ADA63419A3

Inner bearing

Bearing

Pinion NOTE: Once the bearing has cooled down, lightly lubricate bearing with SAE85W90 oil.

NOTE: Lightly lubricate bearing with SAE85W90 oil.

14

9

GUID-E9B2C1BC-89A1-4158-AA1C-D01687582C31

GUID-E5C1C45A-CDBA-4E10-8496-C6E447B45035

Snap ring

Pinion

7 GUID-E3676C58-288E-4F15-B071-DB11DE14CEB8

Flange


Model

Page

T4 HiTech

51

T6

6 GUID-B551B47E-2C1E-4A0A-B17C-69755DA69029

4

Shim

300 N·m

GUID-AD6305E6-4797-48BD-BB25-2D770C779B7B

Example: S1 = 0.75 mm.

Special tool

NOTE: In order to hold the shim in position, apply grease to it.

Nut If torque exceeds the maximum value, then the size of shim "S1" needs to be increased. If torque does not reach the minimum value, then the size of shim "S1" needs to be reduced. If bearings are not new, check the static torque; if bearings are new, check the continuous torque.

4 5 GUID-DC138E5D-A1DF-4047-A14F-3311B919A5D3

Nut Washer

2 - 4 N·m GUID-DF319D36-2607-4884-AB61-FC42E25C875C


Model

Page

T4 HiTech

52

T6

T8 8

4 GUID-9200CBD3-7323-4B51-A5CA-4B18363F7871

GUID-2E67E876-C851-4651-80F9-014103809545

Special tool

Special tool

Nut

Sealing ring

7

4 10

5 GUID-C6E7B70D-6772-4DD0-A376-2E6C1DEA55CA

Nut

GUID-331DB3FC-D0A1-420D-AD23-53E10F32207D

Flange

Washer

O-ring

7

7

GUID-A6153C73-D489-4225-8436-F8774DC018FA

Flange

GUID-4FAE7656-F640-4D19-8F26-87B74CD86FB6

Flange


Model

Page

T4 HiTech

53

Loctite 243 200 N·m

1

5

4

GUID-3A6D0921-4B07-4328-8D93-1613D3CAA227

Nut GUID-CD7AE23C-4D6C-4ECA-BF65-B693E8AE298E

Washer

Arm

T6

4

300 N·m GUID-2F346F2D-DA92-4E7D-9528-C7B43C967C89

Special tool Nut

2

GUID-354042AC-DF39-4791-BF22-085EC8990B18

Differential unit

Air suspension of front axle

Model

Page

T4 HiTech

1

Technical specifications..................................................................................1 Front axle suspension................................................................................1 Shock absorbers........................................................................................1 Tightening torques..................................................................................... 1 AIRES front axle air suspension..................................................................... 2 Levelling valve................................................................................................ 4 Rubber bellows............................................................................................... 7

Adjusting the levelling valve............................................................................ 1 Removing the rubber bellows......................................................................... 2 Fitting the rubber bellows................................................................................ 3

Air suspension of front axle 20.1.2015

Model

Page

T4 HiTech

1

Extraequipment

Availableforallfrontaxletypes

Front axle weight of tractor with air suspension

120 kg heavier than corresponding model without air suspension

Permissibleaxleloading

Thesameasforfrontaxleswithoutsuspension

Extreme pressure values

bar 8

Suspensiontraveloffrontaxle

+45/-50mm

Fronttyres'turningangles

Thesameaswithoutfrontsuspension

Axle turning angles

The same as without front suspension

Automatic level control

Independent of front axle load

Hydraulic shock absorber

2 pcs

Travel

420 mm mm ±4 322 -

Middle position

371 mm

M10, 8x 25±3 Nm M16(10.9), 5x 300 Nm

M8(12.9), 35x 40 Nm M24(8.8), 2x 400 Nm

M16(12.9), 11x 300 Nm

M14(12.9), 4x 220 Nm M12(8.8), 6x 80 Nm

M10, 8x 25±3 Nm

M16(12.9), 4x 340 Nm

GUID-38CA1245-597E-474D-A027-990EDF2EBE1F


Model

Page

T4 HiTech

2

P

3 1

2

4 5 6

7

5 8

10

Y55 -4

Y55

5 9

7

1

Y55 -3

P S117

A1Y

B1F

11

11

GUID-E41F23C1-A9C3-4B51-904C-0F8392208AFE


1. 2. 3. 4. 5. 6. 7. 8. 9.

Model

Page

T4 HiTech

3

Shock absorber Front piece Oil sump Hinge pin Grease nipple for subframe bearing Subframe Rubber bellow Levelling valve Feeler linkage of the suspension position

10. Configuration with AutoComfort 11. Bearing bush hole matches the greasing hole

A1Y

ECU, SUS1

B1F

Sensor, front axle suspension position

S117

Switch, cabin suspension calibration

Y55

Valve block, AutoComfort

Y55–3

Solenoid valve, AutoComfort axle up

Y55–4

Solenoid valve, AutoComfort axle down

The front axle air suspension is an extra equipment that can be fitted for all front axle types. The front axle air suspension consists of shock absorbers, rubber bellows, air pipes and suspension frame parts. The upper ends of the shock absorbers are fitted to the front piece and the subframe attaches to the engine oil sump. All the air pipes are made of nylon pipes and quick couplings. There are two shock absorbers of a liquid type. The shock absorbers are attached with the aid of bushings, which have rubber damping. If the shock absorbers are damaged, driving is uncomfortable because the front axle suspension and oscillations will take longer to stabilize after driving over pot holes or on rough terrain. The air suspension without AutoComfort has a levelling valve, which maintains the height of the suspension system (height of the rubber bellows) regardless of the loading on the front axle. The system can be unpressurised, for example, by turning the feeler linkage of the levelling valve. With AutoComfort the front axle air suspension control unit (A1Y) reads the front axle position sensor (B1F) and controls the front axle suspension through solenoid valves axle up (Y55–3) and axle down (Y55–4). Front axle suspension control is disabled when the parking brake is engaged or when braking. The system can be unpressurised by reloading the control unit (SUS1) parameters, which lowers the air suspension to the lowest position. The system must be calibrated then to make it functional. : Although the engine is stopped, the suspension system remains under pressure. Make the system unpressurised always before maintenance work.


Model

Page

T4 HiTech

4


P

1

2 3

4

5

6

7

8

9

9

10 P

1

2 3

4

5

7

6

8

9

9

10 GUID-7E5BB315-4DD6-4929-B8A0-3F839924A244

1. 2. 3. 4. 5. 6. 7.

Port 1 Valve A Valve B Port 21 Passage Port 22 Sleeve

Model

Page

T4 HiTech

5


Model

Page

T4 HiTech

6

8. Cam pin 9. Link 10. Hole

When the loading on the front axle increases, the tractor front end starts to move downwards. The levelling valve link pushes the sleeve upwards to open position. Valve B opens and compressed air flows from the reservoir through port 1 and valve A into the suspension rubber bellows. The pressure in the rubber bellows increases and the tractor front end raises to the normal horizontal position. When the loading on the front axle decreases, the tractor front end starts to move upwards. The levelling valve link moves downwards closing the valve B and opening a passage to the hole. The pressure decreases in the rubber bellows and the excess air flows out through the hole. The tractor front end lowers to the normal horizontal position.


max Ø 255 Ø 197

1

Q = 2.8 - 7.1 dm

3

0 3 2 5 7

25 M10 GUID-A5329350-0670-4617-8F76-52F1CAED8CF5

1. Pressure air intake

Model

Page

T4 HiTech

7


Before you start: : Although the engine is stopped, the suspension system remains under pressure. Make the system unpressurised always before maintenance work.

1

2

m m 6 1 -1 3 1 1

GUID-7C494883-260C-42D0-923B-3CC58F0BEB1D

1. 2.

Horizontal link Vertical link

The valve must stop the lifting movement when the horizontal link line up in the front part of the suspension frame. If the tractor rises more, lower the tractor frame and make the vertical link longer. If the closing angle (link near horizontal position) is reached before the correct height, shorten the vertical link.

Model

Page

T4 HiTech

1


Before you start: : Although the engine is stopped, the suspension system remains under pressure. Make the system unpressurised always before maintenance work.

1. 2.

Remove the cooling unit. Remove the protective cover on the front end.

Model

Page

T4 HiTech

2


Tighten to 25 Nm.

After you finish: • •

Fit the protective cover on the front end. Fit the coolers.

Model

Page

T4 HiTech

3

t4 hitech 00-02

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