Test instructions for output assessment

of T4i engines

1 INTRODUCTION
The present instructions enable assessing the engine output. As this test method uses test
conditions not complying with standards, the measured values may deviate from the
specified guideline values. CLAAS KGaA mbh will therefore not assume any legal liability
relating to the test results.
First of all, the method described here involves checking all machine parameters influencing
the machine output and which may reduce the output when improperly set. At first, the
output-relevant measured values are detected by means of internal and external sensors.
The values can be entered into the test protocol that is available in WebTIC. The machine
output can be assessed using the guideline values.
Note!
A check of engine output can be performed only on engines that have worked for at least
100 operating hours in usual operating conditions!

2 VISUAL INSPECTION
Note!
The checks below are mandatory to achieve a transparent and comparable test result
regarding the engine output.

Check item Details Measure

Machine
Fault message in CEBIS Read fault messages in CEBIS. Remove fault messages, using the
message details in CEBIS.
Fault memory of ADM Read with the CDS. Remove fault messages, using the
and ECM modules information provided in CDS and in
chapter 92 Diagnosis.
General level of wear, Carry out a visual inspection if a Replace the worn component.
especially in the crop worn component obstructs crop
flow section flow.
Additional non-series Check if no additional and non- Remove additional non-series
attachments and series attachment parts or attachments and conversions.
conversions conversions are provided on the
machine.
Machine adjustment Ensure that all machine Readjust the machine.
(JAGUAR) adjustments match the selected
crop adjustments (grass or maize).
Check item Details Measure
Front attachment,
feeder
Front attachment speed Check if the front attachment speed Adapt the speed of the front
matches the feed rate of the feeder attachment.
unit so that even crop flow is
ensured.
Feed rake conveyor belt Check the tension. Check for Tension and/or replace the belt.
(LEXION, TUCANO) damage.
Chopper unit (JAGUAR)
Drive belt Check the tension. Check for Tension and/or replace the belt.
damage.
Knives sharpness Check the sharpness of knives. Sharpen the knives.
Number of knives Check the settings in CEBIS. Change the settings in CEBIS.
Transfer of crop from Check flawless crop transfer from Replace the scraper.
the plain roller scraper the plain roller scraper to the shear
to the shear bar bar, avoid obstacles, e.g. edges.
Lengths of cut Check the length of cut setting in Adjust the lengths of cut, using the
CEBIS. information provided in the
Operator's Manual.
Shear bar Check the cutting gap setting in Adjust the shear bar, using the
CEBIS. Check the condition of the information provided in the
shear bar. Operator's Manual. Replace the
shear bar if necessary.
Adjustment of chopper Check the adjustment of chopper Adjust the chopper bottom plate,
bottom plate bottom plate. using the information provided in the
Operator's Manual.
Corn cracker, discharge accelerator (JAGUAR)
Corn cracker type Check the corn cracker type setting Change the setting in CEBIS.
in CEBIS.
Corn cracker clearance Check the corn cracker clearance Change the setting in CEBIS.
setting in CEBIS.
Corn cracker speed Check against the Operator's Adjust according to the Operator's
difference Manual. Manual.
Discharge accelerator Check the clearance between the Adjust according to the Operator's
discharge accelerator and the back Manual.
panel.
Threshing mechanism, residual grain separation (LEXION,
TUCANO)
Threshing concave Check against the Operator's Adjust according to the Operator's
adjustment Manual. Manual.
Threshing drum speed Check against the Operator's Adjust according to the Operator's
Manual. Manual.
Straw walker or rotor Check against the Operator's Adjust according to the Operator's
speed Manual. Manual.
All drive belts Check the tension. Check for Tension and/or replace the belt.
damage.
Check item Details Measure
Chopper and spreader (LEXION, TUCANO)
Chopper knife Check the sharpness of knives. Sharpen the knives.
sharpness
Shear bar Check shear bar wear. Replace the shear bar.
Adjustment of length of Check against the Operator's Adjust according to the Operator's
cut Manual. Manual.
Chopper drive belt Check the tension. Check for Tension and/or replace the belt.
damage.
Drive and adjustment of Check tension and adjustment of Tension and/or replace the belt.
radial spreader belt. Check for damage.
Drive and adjustment of Check tension and adjustment of Tension and/or replace the belt.
chaff spreader belt. Check for damage.
Chassis
Tyre inflation pressure Check against the Operator's Adjust according to the Operator's
Manual. Manual.
Gearbox oils level Using the Operator's Manual, check Top up the specified gearbox oil.
the manual gearbox and axle drive
oil levels.
Hydraulic, pneumatic and electric systems
Hydraulic circuit Ensure that hydraulic lines are not Replace damaged components.
pinched off or damaged and that
there are no leaks in the hydraulic
circuit.
Hydraulic oil level Check against the Operator's Top up the specified hydraulic oil.
Manual.
Pneumatic brake system Check if the pneumatic brake Remove any leaks.
system is leaky.
Battery voltage Check against the Operator's Replace the battery.
Manual.
Additional lights, Ensure that no additional current Switch off additional lights and
external power consumer is installed. external power consumers.
consumers
Engine
Fuel Check if the fuel quality meets the Use the specified fuel.
requirements of the engine
manufacturer.
Engine oil Check if the engine oil meets Change the engine oil, using the
CLAAS specifications and if it was specified grade.
changed after the specified
maintenance intervals.
Engine oil level Check against the Operator's Top up the specified engine oil
Manual. grade.
Fuel pre-filter and fuel Check if filters are clogged and/or Clean the fuel pre-filter and/or the
filter soiled. fuel filter.
Fuel suction and return Check if lines are clogged, Replace any damaged fuel line.
lines damaged and/or soiled.
Water separator Check the water content in the fuel. Drain water from the water
separator.
Check item Details Measure
Charge air circuit Check if charge air line from the air Replace any damaged components.
filter to the engine is tight, correctly
seated and/or damaged.
Air filter Check if air filter is soiled. Clean air filter and replace if
necessary.
Cooling system
Rotary chaff screen Check if rotary chaff screen is Clean the rotary chaff screen.
clogged.
Fan Check tension of fan drive belt and Replace belt and/or fan.
condition of fan blades.
Radiator elements Check if these elements are Replace the damaged radiator
(water, oil, charge air, damaged, clean and tight. element.
air conditioner
compressor)

3 FUEL LOW PRESSURE MEASUREMENT

The fuel low-pressure measurement is without machine load.

3.1 SPECIAL TOOL

00 1992 866 0 00 1992 892 0 00 1992 889 0

Pressure hose Test device Adapter

00 0216 398 0 00 0216 465 0

Double hollow screw Seal
3.2 PREPARING THE MEASUREMENT

Screw the test device together with the pressure

hose and the ring from the adapter set.

Connect the test device to the fuel filter return

line, using the double hollow screw and the seal.

3.3 PERFORMING THE MEASUREMENT

 Start the diesel engine.

 Set the diesel engine speed rotary switch to slow idling speed. Set the main
gearbox to the neutral position.
 Read the fuel pressure on the pressure gauge and take the value down in the test
protocol.

 Set the diesel engine speed rotary switch to upper idling speed.
 Read the fuel pressure on the pressure gauge and take the value down in the test
protocol.

At the end of the measurement, remove the test device and screw in the hollow screw initially
used with a new seal and to a torque of 50 Nm.
4 CHARGE PRESSURE AND TORQUE MEASUREMENT

4.1 PREPARING THE MEASUREMENT

Plug the latest CDS version into the machine. Open the CDS module below:

 Selecting the machine type

 > Diagnosis > Functions > 01 Engine > 0155 Engine control > Engine output
The engine is fully loaded during fieldwork for measuring the charge pressure and the torque.
Heat up the engine to operating temperature before starting the measurement (coolant
temperature: 80-90 °C).

4.2 PERFORMING THE MEASUREMENT

Note!
To achieve proper and well-founded output measurement, the items listed in the "Visual
inspection" and "Preparation" sections must be respected.

Carry out the output measurement as described below:

 Operate the engine under full load in fieldwork, the engine speed is to be reduced to
the speeds below:
o LEXION: 1800 rpm
o TUCANO: 2100 rpm
o JAGUAR: first 1800 rpm, then down to 1650 rpm
 The measured values can be read on the engine output module in real time.
However, for more precise output assessment we recommend that you record the
output-relevant measuring data with the "Start recording" button. Stop recording after
approx. 30 sec. with the "Stop recording" button.
 The measured data can then be read in the log files. The following signals shall be
selected in the list:
o Atmospheric pressure
o Actual engine torque
o Fuel consumption rate
o Charge pressure (absolute)
o Engine speed
  In the graphics, shift the marking line to a measuring point where the engine speed is
at the desired value (see test protocol of machine in question). Read the measured
values for this measuring point in the upper table in the CDS and take it down in the
test protocol.

Note!
The CDS displays the charge pressure as atmospheric pressure (absolute), i.e. the
atmospheric pressure must be subtracted from the displayed value!
Enter only the actual charge pressure (excess pressure) into the table.

During the test phase, there may be no significant changes (e.g. increase of engine
temperature) on the diesel engine. If necessary, note significant changes in the test protocol.

 Let the diesel engine run without load for a short time after the measurement is
complete.
 Stop the diesel engine.
When the measured charge pressure and the engine torque are in line with the guideline
values or exceed them, the engine output is OK.
If there are deviations from the guideline values, send the completed test protocol to the
CLAAS Service Dept.
Note!
When operating the engine with biodiesel, an output reduction of 10 % min. must be
expected!