Document overview
Workshop Manual PDF for SAME TTCD 7.8 Stage 5, Tractor components – Engine – DEUTZ AG Stage 4-5 family. Document language: English; 403 pages.
The corresponding English table of contents contains 22 sections and 188 individual topics.
Main sections included
- Safety
- General Information
- Technical data
- ENGINE – Disassembly, assembly and checks
- ENGINE ANCILLARIES – Disassembly, assembly and checks
- Electrical system
Document details
- Brand: SAME
- Family: Tractor components – Engine – DEUTZ AG Stage 4-5
- Model: TTCD 7.8 Stage 5
- Document type: Workshop Manual
- Language: English
- Pages: 403
- File size: 75.87 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME TTCD 7.8 Stage 5.
Complete table of contents
Safety
- Safety
General Information
- Introduction
- Tightening Torques
Technical data
- Pressure transducer (exhaust gas backpressure) – (B60)
- Differential pressure transducer (diesel particulate filter) – (B61)
- Differential pressure transducer (diesel particulate filter) – (B58)
- Pressure sensor (Rail) – (B49)
- Pressure transducer (lubricant oil) – (B6) / (fuel) – (B51)
- Pressure/temperature sender (engine intake air) – (B48)
- Temperature sender (cooling system) – (B43)
- Temperature sender (exhaust gas recirculation) – (B64)
- Temperature sender (intake air, ambient air) – (B74)
- Temperature sender (ahead of and after diesel oxidation catalyst) – (B65)
- Temperature sender (ahead of and after diesel oxidation catalyst) – (B65)
- Speed sensor (crankshaft) – (B40.2)
- Speed sensor (camshaft) – (B40.1) / (crankshaft) – (B40.2)
- Speed sensor (camshaft) – (B40.1)
- NOx sensor (SCR ahead of catalytic converter) – (B54)
- NOx sensor (SCR ahead of catalytic converter) – (B54)
ENGINE – Disassembly, assembly and checks
GENERIC
- Removing and fitting the mounting plate (ribbed V-belt, level 1)
- Removing and fitting the mounting console (poly-V-belt, level 2)
- Removing and fitting the fan mount (fastener elements)
- Removal and assembly of the fan support
- Removing and refitting the idler roller (coolant pump – poly-V-belt, level 1)
- Removing and refitting idler roller (fan mount – poly-V belt, level 1)
- Mount (Assembly parts – poly-V belt, level 2)
- Idler roller (poly-V belt, level 1)
- Removing and fitting the belt tensioner (ribbed V-belt, level 2)
CYLINDER BLOCK
- Measure the pressure in the crankcase
- Disassembling and assembling crankcase breather
- Blanking tool (crankcase)
- Disassembling and assembling the connector housing
- Blanking elements (crankcase, PTO-A)
CRANKSHAFT
- Replacing the crankshaft seal ring
- Disassembling/assembling crankshaft wear sleeve (side opposite flywheel)
- Disassembling and assembling the front cover (fixing elements)
- Removing and refitting crankshaft bearing cap
- Disassembling and assembling the V-belt pulley
- Disassembling and assembling the torsional vibration damper
- Removing and fitting the vibration damper
- Removing and fitting the vibration damper
- Removing and fitting the flywheel (fastener components)
- Assembly and disassembly of the crankshaft bearing
- Check the crankshaft
- Check the endfloat of the crankshaft
- Removing and fitting the crankshaft bearing
- Check the crankshaft bearings
- Replacing the crankshaft seal ring (flywheel side).
CYLINDERS – PISTONS – CONNECTING RODS
- Checking cylinder sleeve protrusion
- Cylinder liner check
- Fitting and removing the cylinder sleeve
- Removing and fitting the cylinder sleeve (milled) together with the piston and the connecting rod shank.
- Assembly and disassembly of piston cooling nozzles
- Disassembly and reassembly of connecting rod shank
- Check the connecting rod shank
- Disassembling and assembling the piston
- Disassembling and assembling the piston rings
- Check the piston rings
- Measuring piston protrusion
TIMING
- Disassembling and assembling the gearbox
- Assembly and disassembly of the camshaft
- Check the camshaft
- Removing and fitting the camshaft bearing
- Checking the camshaft bearing
CYLINDER HEAD
- Compression test
- Removing and fitting the cylinder head cover
- Disassembling and assembling the cylinder head (fasteners)
- Assembly and disassembly of the valves
- Checking valves, valve guides, valve springs and valve recess
- Replacing the valve stem gasket (with cylinder head installed on engine)
- Eye-bolt for transporting (cylinder head)
- Checking and adjusting valve clearance
- Removing and fitting the rockers and rocker arm carriers
- Disassembly and assembly of the control elements
LUBRICATION
- Removing and fitting lubricant oil sump (heavy version)
- Removing and fitting lubricant oil sump (heavy version)
- Removing and fitting the lubricant oil filter
- Removing and fitting the lubricant oil filter
- Screw plug (lubricant oil sump)
- Hole blanking screw (cast iron lubricant oil sump)
- Oil filler neck
- Removing and fitting lubricant oil cooler
- Disassembling and assembling the lubricant oil cooler
- Removing and refitting lubricant oil cooler housing (fastener elements)
- Removing and fitting the lubricant oil cooler housing
- Blanking elements (lubricant oil cooler housing)
- Blanking elements (lubricant oil cooler housing)
- Blanking elements (lubricant oil cooler housing)
- Coolant pipes (Lubricant oil cooler housing)
INJECTION SYSTEM
- Replacing the injector bush
- Cleaning the injector bush
- Cleaning the injector bush seat
- Disassembly and assembly of the fuel control unit (fastening elements)
- Disassembling and completing assembly of the fuel control unit (2000 bar injection system)
- Removing and fitting the high pressure pump (fastener elements)
- Removing and fitting injector (with bronze seal disc) (2000 bar injection system)
- Disassembling and assembling the fuel delivery pump (fastener elements)
- Disassembling and assembling the cylinder head (fasteners)
- Manual fuel pump
- Removing and fitting the fuel line (fuel control block – high pressure pumps)
- Disassembling and assembling the rail (2000 bar injection system)
- Disassembling and assembling the rail (2000 bar injection system)
- Fitting and removing the pressure limiting valve (Rail)
- Fitting and removing the rail pressure sensor
- Fuel pipes (connectors)
- Fuel pipes (fuel delivery pump, fuel filter, fuel control block, rail, cylinder head)
- Vibration damper (installation position)
COOLING
- Removing and fitting the coolant pump
- Assembling and disassembling the thermostat
- Check the thermostat (after removing)
- Removal and installation of the thermostat housing
- Removing and fitting the connector pipe (coolant pump – exhaust gas recirculation)
- Removing and fitting the connector pipe (thermostat housing, exhaust gas recirculation, coolant line)
- Blanking elements (thermostat housing)
- Check the seal of the cooling system
- Charge air radiator
INTAKE MANIFOLD
- Disassembling and assembling charge air pipe
- Disassembling and assembling the exhaust manifold
- Removing and fitting the exhaust flange (radiator – mixer pipe)
- Removing and fitting the exhaust flange (radiator – Venturi pipe)
- Disassembling and assembling the butterfly valves
- Disassembling and assembling the radiator
- Disassembling and assembling the regulator
- Disassembling and assembling the Venturi pipe
- Disassembling and assembling the temperature sender
- Removing and fitting the pressure transducer
- Heat shield (exhaust pipe)
- Mount (radiator – exhaust gas recirculation)
TURBOCHARGER
- Fitting compensator (turbocharger)
- Pipe (exhaust backpressure pressure transducer).
- Pipe (exhaust backpressure pressure transducer).
- Disassembling and assembling the turbocharger
- Removing and fitting the lubricant oil pipe (turbocharger with regulator)
- Removing and fitting the lubricant oil pipe (turbocharger without regulator)
- Removing and fitting the adapter (lubricant oil return line)
- Removing and fitting the lubricant oil return pipe (lower section) (turbocharger with regulator)
- Removing and fitting the lubricant oil return pipe (lower section) (turbocharger without regulator)
- Removing and fitting the lubricant oil return pipe (upper section) (turbocharger with regulator)
- Removing and fitting the lubricant oil return pipe (upper section) (turbocharger without regulator)
- Removing and fitting the compensator (connection between the two turbochargers)
- Connector cable (turbocharger without regulator – charge air intercooler)
- Connector cable (turbocharger without regulator – charge air intercooler)
- Connector cable (turbocharger without regulator – charge air intercooler)
ENGINE ANCILLARIES – Disassembly, assembly and checks
GENERIC
- Wiring harness (fasteners)
- Wiring harness (fasteners, connector)
- Protective cap (relay)
- Heater (connector line)
- Flushing the SCR (Selective Catalytic Reduction) delivery pump
- Flushing/Checking SCR (Selective Catalytic Reduction) metering unit
- Flushing the SCR (Selective Catalytic Reduction) pipe (delivery pump – metering unit)
RADIATORS – FANS
- Disassembling and assembling the heater
- Disassembling and assembling the mixer pipe
- Disassembling and assembling the butterfly valve
- Disassembling and assembling the heater
- Disassembling and assembling the heater
STARTER MOTOR
- Shield plate
- Connection (Starter)
- Connection (Starter)
- Starter (fasteners)
- Starter (fasteners)
EXHAUST SILENCER
- Removing and refitting the diesel particulate filter (module size 11.25″)
- V-Band clamp.
ELECTRIC COMPONENTS
- Pressure transducer (exhaust back-pressure).
- Air pressure/temperature sender (intake air)
- Disassembling and assembling alternator (poly-V-belt, level 1)
- Removing and refitting alternator (poly-V-belt, level 2)
- Removing and fitting the V-belt pulley (version with locking cone)
- Alternator
- Alternator
- Alternator
- Disassembly and refitting of the intake air pressure/temperature sender
- Fitting and removing the cable guide
- Temperature sender (coolant)
- Fitting the pressure transducer (intake air)
- Fitting the pressure transducer (fuel pressure / lubricant oil pressure)
- Relay (heater, thermo-starter, glow plugs)
- Relay (thermo-starter)
- Camshaft speed sensor
- Crankshaft speed sensor
- Disassembling and assembling the NOx sensor
- Disassembling and assembling the pressure transducer (exhaust back-pressure)
- Assembling the SCR (Selective Catalytic Reduction) metering unit
- Temperature sender (ahead of and after diesel oxidation catalytic converter)
- Temperature sender (exhaust gas)
- Temperature sender (inlet air and ambient air temperature)
- SCR delivery pump (Selective Catalytic Reduction)
Electrical system
- Connector cable (relay – alternator)
- Connector cable (relay – heater)
