MASSEY FERGUSON 4600, 4609, 4608, 4610 Service Manual

MF 4600

Series Tractors

Models: 4608 / 4609 / 4610

SERVICE MANUAL

FROM MASSEY FERGUSON

Table of contents

4608 / 4609 / 4610 Service Manual

1 Introduction ..............................................................1-1

1.1 Introduction .......................................................1-3

1.1.1 The service manual ...............................................1-3

1.1.2 Replacement parts ...............................................1-3

1.1.3 Units of measurement .............................................1-3

1.1.4 Machine identification .............................................1-3

1.1.5 Serial number plate ...............................................1-4

1.1.6 Engine identification ..............................................1-4

1.1.7 Chassis number .................................................1-5

1.2 Specifications ......................................................1-6

1.2.1 Engine specifications ..............................................1-6

1.2.2 Electrical specifications ............................................1-6

1.2.3 Transmission specifications .........................................1-7

1.2.4 Power takeoff specifications ........................................1-7

1.2.5 Front axle specifications ...........................................1-7

1.2.6 Rear axle specifications ............................................1-8

1.2.7 Brake specifications ..............................................1-8

1.2.8 Hydraulic specifications ............................................1-8

1.2.9 Fuel specifications ................................................1-8

1.2.10 Operating slope angle ............................................1-9

1.2.11 Lubrication specifications ..........................................1-9

1.2.12 Capacities ....................................................1-10

1.2.13 Maximum load capacity ..........................................1-10

1.2.14 Wheel bolt torque chart ..........................................1-11

1.2.15 Tire inflation pressures ...........................................1-12

1.3 General dimensions ...............................................1-14

1.3.1 Platform tractor dimensions ........................................1-14

1.3.2 Cab tractor dimensions ...........................................1-15

1.4 Lubrication / fill points ............................................1-17

1.4.1 Lubrication and maintenance chart ...................................1-17

1.4.2 Initial lubrication and maintenance chart ...............................1-18

1.4.3 Lubrication fill and drain locations ....................................1-19

1.5 General precautions for disassembly and installation ................1-20

1.5.1 Precautions for disassembling and installing ............................1-

1.5.2 Precautions when installing according to standards parts ...................1-20

1.6 Tightening torque chart ...........................................1-23

1.7 Conversion table ..................................................1-25

20

2 Safety ................................................................... 2-1

2.1 Introduction .......................................................2-3

2.1.1 Safety alert symbol ...............................................2-3

2.1.2 Informational messages ........................................... 2-3

2.1.3 Safety messages ................................................ 2-3

2.1.4 Safety signs ....................................................2-4

2.2 Operation ........................................................2-11

2.2.1 Prepare for operation .............................................2-11

2.2.2 Roll over protective structure .......................................2-11

2.2.3 General information ..............................................2-11

2.2.4 Personal protective equipment ......................................2-15

2.2.5 Seat instruction .................................................2-15

2.2.6 Shield and guards ...............................................2-15

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2.2.7 Power takeoff safety .............................................2-16

2.2.8 Exhaust warning ................................................2-17

2.2.9 Flying debris ...................................................2-17

2.3 Travel on public roads .............................................2-18

2.4 Maintenance ......................................................2-20

2.4.1 General maintenance information ....................................2-20

2.4.2 Fire prevention and first aid ........................................2-21

2.4.3 High pressure leaks ..............................................2-22

2.4.4 Engine safety ..................................................2-23

2.4.5 Fuel safety ....................................................2-24

2.4.6 Battery safety ..................................................2-25

2.4.7 Tire safety .....................................................2-25

2.4.8 Replacement parts ..............................................2-26

3 Engine ...................................................................3-1

3.1 Component access .................................................3-3

3.1.1 Opening the engine cover ..........................................3-3

3.2 Radiator ...........................................................3-4

3.2.1 Removing the radiator .............................................3-4

3.3 Removing the engine ...............................................3-6

3.4 Installing the engine ..............................................3-10

3.5 Fuel tank .........................................................3-11

3.5.1 Removing the fuel tank ...........................................3-11

3.6 Electronic diagnostic tool ..........................................3-14

3.6.1 Engine service tool software license .................................3-14

3.6.2 Connecting the electronic diagnostic tool ..............................3-14

3.7 Engine service manual ............................................3-15

3.7.1 Insert the engine service manual here ................................3-15

4 Power train .............................................................. 4-1

4.1 Separating the engine from the front transmission ...................4-3

4.2 Separating the front and mid-transmission housings .................4-9

4.3 Separating the mid and rear transmission housings .................4-13

4.4 Separating the rear axle from the rear transmission case ............4-17

4.5 Attaching the rear axle to the rear transmission case ................4-19

4.6 Power shuttle transmission ........................................4-20

4.7 Power train .......................................................4-23

4.8 Gear ratios .......................................................4-26

4.9 Shuttle clutch .....................................................4-28

4.9.1 Assembling precautions for power shuttle .............................4-29

4.10 Clutch pack ......................................................4-30

4.10.1 Reverse clutch pack components ...................................4-30

4.10.2 Disassembling the reverse clutch ...................................4-31

4.11 Input gears ......................................................4-32

4.11.1 Removing the input gear .........................................4-32

4.11.2 Disassembling the input gear ......................................4-32

4.11.3 Assembling the input gears .......................................4-33

4.11.4 Disassembling the rear and mid-transmission housing ....................4-34

4.11.5 Input gears ...................................................4-36

4.12 Transmission main change gears .................................4-40

4.12.1 Assembling precautions for main gear system .........................4-

4.12.2 Main shift lever ................................................4-42

4.12.3 Assembling precautions for the main shift lever ........................4-43

4.12.4 Disassembling the high-low gear ...................................4-44

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4.13 Creeper gear .....................................................4-45

4.13.1 Creeper gear components ........................................4-45

4.13.2 Disassembling the creeper gear ....................................4-45

4.13.3 Assembling the creeper gear ......................................4-49

4.14 Transmission range change gears .................................4-53

4.14.1 Range gear shift ...............................................4-53

4.14.2 Installing the range gear shift ......................................4-54

4.14.3 Range shift linkage .............................................4-55

4.14.4 Independent power takeoff .......................................4-56

4.14.5 Power takeoff clutch ............................................4-57

4.14.6 Assembling power takeoff precautions ...............................4-58

4.14.7 Four-wheel drive gears, if equipped .................................4-58

4.14.8 Assembling four-wheel drive, if equipped .............................4-59

4.14.9 Four-wheel drive gear system .....................................4-60

4.14.10 Two wheel-drive gear system ....................................4-61

4.14.11 Power takeoff speed ...........................................4-61

4.14.12 Power takeoff lever ............................................4-63

4.14.13 Power takeoff link check system ..................................4-63

4.14.14 Low profile lever ..............................................4-63

5 Cab and platform .........................................................5-1

5.1 Platform ...........................................................5-3

5.1.1 Removing the platform ............................................5-3

5.1.2 Removing the floor mat and steps ...................................5-11

5.1.3 Installing the floor mats and steps ...................................5-12

5.2 Cab ..............................................................5-13

5.2.1 Removing the cab ...............................................5-13

5.2.2 Installing the cab ................................................5-19

5.2.3 Removing the cab roof ...........................................5-20

5.2.4 Installing the cab roof ............................................5-20

5.2.5 Opening the roof ................................................5-21

5.2.6 Removing the door ..............................................5-22

5.2.7 Installing the door ...............................................5-22

5.2.8 Adjusting the door tilt ............................................5-24

5.2.9 Adjusting the opening angles of the door ..............................5-24

5.2.10 Installing the door lock ...........................................5-25

5.2.11 Relay position .................................................5-26

5.2.12 Cab lamp ....................................................5-27

5.2.13 Wiper and flood light switches .....................................5-27

5.2.14 Air conditioner control panel .......................................5-28

5.2.15 Air conditioning dual pressure switch ................................5-28

5.2.16 Cab wire harness ..............................................5-29

5.2.17 Installing the speaker system ......................................5-29

5.2.18 Installing the antenna assembly ....................................5-31

5.3 Seat ..............................................................5-34

5.3.1 Removing the seat ..............................................5-34

5.3.2 Installing the seat ...............................................5-35

5.4 Roll over protective structure ......................................5-36

5.4.1 Removing the roll over protective structure .............................5-36

5.4.2 Installing the roll over protective structure .............................5-36

5.5 Steering column ..................................................5-37

5.5.1 Removing the steering column .....................................5-37

5.5.2 Installing the steering column ......................................5-37

5.6 Steering wheel ...................................................5-38

5.6.1 Removing the steering wheel ......................................5-38

5.6.2 Installing the steering wheel .......................................5-38

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5.7 Mirrors ...........................................................5-39

5.7.1 Adjusting the mirror arm assembly ...................................5-39

5.8 Air conditioning system ...........................................5-41

5.8.1 Air conditioner outline ............................................5-41

5.8.2 Air conditioner system specifications .................................5-41

5.8.3 Drain hoses ...................................................5-42

5.8.4 Air conditioner hoses .............................................5-43

5.8.5 Heater hose ...................................................5-45

5.8.6 Installing the insulator ............................................5-48

5.8.7 Compressor ...................................................5-49

5.8.8 Condenser ....................................................5-50

5.8.9 Receiver dryer ..................................................5-51

5.8.10 Air conditioner unit .............................................5-51

5.8.11 Expansion valve ................................................5-52

5.8.12 Air conditioning dual pressure switch ................................5-52

5.8.13 Thermostat ...................................................5-53

5.8.14 Air conditioner operation .........................................5-53

5.8.15 Air conditioner inspection and maintenance ...........................5-53

5.8.16 Refrigerant amount check ........................................5-54

5.8.17 Air conditioner compressor belt ....................................5-55

5.8.18 Adjusting the air conditioner compressor belt ..........................5-56

5.8.19 Servicing the condenser .........................................5-56

5.8.20 Changing the air conditioner filter ...................................5-58

5.8.21 Maintenance ..................................................5-60

5.8.22 Removing the air conditioner compressor .............................5-60

5.8.23 Installing the air conditioner compressor ..............................5-61

5.8.24 Removing the condenser .........................................5-62

5.8.25 Installing the condenser ..........................................5-63

5.8.26 Removing the receiver dryer ......................................5-63

5.8.27 Installing the receiver dryer .......................................5-64

5.8.28 Removing the air conditioner unit ...................................5-64

5.8.29 Air conditioner control lever cable ...................................5-65

5.8.30 Shutter for inside/outside air control .................................5-65

5.8.31 Assembling the air conditioner and relative components ..................5-66

5.8.32 Safety precautions when charging the refrigerant .......................5-67

5.8.33 Connecting the service gauge manifold ..............................5-69

5.8.34 Evacuating the air conditioning system ...............................5-69

5.8.35 Preforming airtight check 1 .......................................5-70

5.8.36 Preforming the airtight check 2 ....................................5-70

5.8.37 Charging from the high pressure side ................................5-71

5.8.38 Charging from the low pressure side ................................5-72

5.8.39 Detaching the service gauge manifold ...............................5-74

5.9 Troubleshooting the air conditioner system .........................5-75

6 Frame and axles ..........................................................6-1

6.1 Hydrostatic steering ................................................6-3

6.1.1 Construction ....................................................6-3

6.1.2 Major components ...............................................6-4

6.1.3 Orbit roll disassembly .............................................6-4

6.1.4 Disassembling the gerotor side ......................................6-5

6.1.5 Disassembling the control side ......................................6-6

6.1.6 Inspecting the orbit roll ............................................6-9

6.1.7 Assembling the control side .........................................6-9

6.1.8 Assembling the gerotor side .......................................6-12

6.1.9 Orbit roll specifications ...........................................6-14

6.1.10 Troubleshooting ...............................................6-14

6.2 Fender ...........................................................6-17

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6.2.1 Removing the fender .............................................6-17

6.2.2 Installing the fender ..............................................6-18

6.3 Engine cover ......................................................6-19

6.3.1 Removing the engine cover ........................................6-19

6.3.2 Installing the engine cover .........................................6-19

6.3.3 Head lamp and engine cover net ....................................6-19

6.3.4 Side cover .....................................................6-20

6.4 Three-point linkage and drawbar ...................................6-21

6.4.1 Three-point linkage ..............................................6-21

6.4.1.1 Draw bar ...............................................6-26

6.4.1.2 Maintaining drawbar components .............................6-26

6.4.2 Removing the lift cylinder case .....................................6-27

6.5 Rear axle .........................................................6-29

6.5.1 General Information ..............................................6-29

6.5.2 Rear axle and brakes .............................................6-29

6.5.3 Rear differential lock system and housing ..............................6-31

6.6 Rear axle housing and differential gears ............................6-32

6.6.1 Disassembling the rear axle housing ..................................6-32

6.6.2 Inspecting the rear axle and the brakes ................................6-34

6.6.3 Brake discs ....................................................6-34

6.6.4 Separator plates ................................................6-35

6.7 Ring gear and pinion ..............................................6-36

6.7.1 Removing the ring gear and the pinion ................................6-36

6.7.2 Disassembling the ring gear and the pinion .............................6-37

6.7.3 Inspecting the ring gear and pinion assembly ...........................6-38

6.7.4 Assembling the ring gear and the pinion ...............................6-38

6.7.5 Installing the ring gear and the pinion .................................6-42

6.7.6 Backlash specification ............................................6-42

6.7.7 Thrust collar specification .........................................6-43

6.7.8 Tooth contact pattern ............................................6-43

6.7.9 Assembling the pinion bevel .......................................6-45

6.8 Brakes ...........................................................6-46

6.8.1 Disassembling the brakes .........................................6-47

6.8.2 Inspecting the brake discs and the separator plates .......................6-47

6.8.3 Checking the brake adjustment .....................................6-47

6.8.4 Adjusting the brakes .............................................6-48

6.9 Differential .......................................................6-49

6.9.1 Differential lock .................................................6-49

6.10 Front axle .......................................................6-51

6.10.1 Removing the front axle ..........................................6-51

6.10.2 Front axle component inspection ...................................6-52

6.10.3 Installing the front axle ...........................................6-54

6.10.4 Front axle components ..........................................6-55

6.10.5 Front axle specifications .........................................6-57

6.10.6 Four-wheel drive shaft components .................................6-57

6.10.7 Hydraulic steering ..............................................6-58

6.10.8 Two-wheel drive front axle component ...............................6-60

6.10.9 Two-wheel drive steering controller system ...........................6-63

6.10.10 Two-wheel drive tie rod system ...................................6-63

6.11 Front differential (four-wheel drive only) ...........................6-64

6.11.1 Disassembling the pinion carrier ....................................6-64

6.11.2 Overhauling the pinion carrier ......................................6-65

6.11.3 Inspecting the pinion carrier .......................................6-66

6.11.4 Assembling the pinion carrier ......................................6-66

6.11.5 Disassembling the differential gears .................................6-67

6.11.6 Inspecting the differential gears ....................................6-67

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6.11.7 Assembling the differential gears ...................................6-68

6.11.8 Final drive components ..........................................6-70

6.11.9 Removing the wheel shaft seal/cover ................................6-71

6.11.10 Installing the wheel shaft seal/cover ................................6-72

6.11.11 Removing the front axle center section ..............................6-74

6.11.12 Installing the front axle center section ...............................6-74

6.11.13 Removing the front axle bracket oil seal .............................6-74

6.11.14 Installing the front axle bracket oil seal ..............................6-75

6.12 Final drive housing (four-wheel drive only) ........................6-76

6.12.1 Disassembling the final drive housing ................................6-76

6.12.2 Inspecting the final drive housing ...................................6-77

6.12.3 Assembling the final drive housing ..................................6-78

6.12.4 Tie rod assembly ...............................................6-80

6.13 Front wheel alignment ...........................................6-81

6.13.1 Adjusting the front wheel alignment .................................6-81

6.13.2 Steering free play ..............................................6-81

6.14 Front axle troubleshooting .......................................6-82

7 Electrical .................................................................7-1

7.1 Wire color chart ....................................................7-3

7.2 Power shuttle general information ..................................7-5

7.3 Wiring diagrams ...................................................7-6

7.3.1 Battery wiring diagram ............................................ 7-7

7.3.2 Instrument panel wiring diagram .....................................7-8

7.3.3 Head lamp wiring diagram ..........................................7-9

7.3.4 Controller wiring diagram ..........................................7-10

7.3.5 Cab wiring diagram ..............................................7-11

7.3.6 Main wiring diagram .............................................7-12

7.3.6.1 .....................................................7-13

7.3.6.2 .....................................................7-13

7.3.7 Engine wiring diagram ............................................7-14

7.3.7.1 .....................................................7-15

7.3.8 Controller area wiring diagram ......................................7-15

7.3.8.1 .....................................................7-16

7.3.9 Cab1 wiring diagram .............................................7-16

7.3.9.1 .....................................................7-18

7.3.10 Cab2 wiring diagram ............................................7-18

7.4 Instruments and controls ..........................................7-21

7.4.1 Removing the console ............................................7-21

7.4.2 Mater panel switch ..............................................7-21

7.4.3 Removing the instrument panel .....................................7-22

7.4.4 Installing the instrument panel ......................................7-24

7.4.5 Instrument panel switch location diagram ..............................7-27

7.4.6 Cab switch location diagram .......................................7-28

7.4.6.1 .....................................................7-28

7.4.7 Lever guide switch location diagram ..................................7-29

7.4.8 Main fuse box - platform tractor .....................................7-31

7.4.9 Main fuse box - cab tractor ........................................7-33

7.5 Valves ............................................................7-35

7.5.1 Power shuttle valve ..............................................7-35

7.5.2 Power take-off valve .............................................7-44

7.5.3 Solenoid valves .................................................7-46

7.6 Position of the main electrical parts ................................7-50

7.6.1 Position of sub-change lever position sensor ............................7-50

7.6.2 Position of the air conditioner controller panel ...........................7-50

7.6.3 Position of the air conditioner controller unit ............................7-51

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7.6.4 Position of the cabin harness assembly ...............................7-51

7.6.5 Position of the engine harness coupler ................................7-52

7.6.6 Position of the head lamp .........................................7-52

7.6.7 Position of the horn ..............................................7-52

7.6.8 Position of the starter ............................................7-53

7.7 Sensor initial adjustment ..........................................7-54

7.7.1 Calibrating the three-point hitch .....................................7-54

7.7.2 Lift arm and draft sensor ..........................................7-57

7.7.3 Control lever ...................................................7-58

7.7.4 Fuse box ......................................................7-58

7.7.5 Depth dial .....................................................7-59

7.7.6 Lift lamp ......................................................7-59

7.7.7 Main switch ...................................................7-60

7.7.8 Calibrating the clutch pedal switch and sensor ..........................7-60

7.7.9 Clutch pedal ...................................................7-62

7.7.10 Clutch pedal sensor .............................................7-63

7.7.11 Clutch pedal switch .............................................7-63

7.7.12 Forward/reverse lever ...........................................7-64

7.7.13 Calibrating the clutch initial time ....................................7-64

7.7.14 Range shift lever ...............................................7-65

7.7.15 Gear shift lever ................................................7-65

7.7.16 Parking lever switch ............................................7-66

7.7.17 Brake pedal switch .............................................7-66

7.7.18 Throttle lever ..................................................7-67

7.7.19 Instrument panel ...............................................7-67

7.8 Electrical and hydraulic control system .............................7-68

7.9 Main clutch system ...............................................7-70

7.10 Electronic diagnostic tool .........................................7-72

7.10.1 Engine service tool software license ................................7-72

7.10.2 Connecting the electronic diagnostic tool .............................7-72

7.11 Fault code tree ...................................................7-73

7.12 Diagnostic codes .................................................7-75

7.12.1 SPN 1001 FMI 1 ...............................................7-75

7.12.2 SPN 1001 FMI 2 ...............................................7-78

7.12.3 SPN 1001 FMI 3 ...............................................7-81

7.12.4 SPN 1002 FMI 1 ...............................................7-84

7.12.5 SPN 1002 FMI 2 ...............................................7-87

7.12.6 SPN 1002 FMI 3 ...............................................7-90

7.12.7 SPN 1004 FMI 1 ...............................................7-93

7.12.8 SPN 1004 FMI 2 ...............................................7-96

7.12.9 SPN 1004 FMI 3 ...............................................7-99

7.12.10 SPN 3055 FMI 1 .............................................7-102

7.12.11 SPN 3055 FMI 2 .............................................7-104

7.12.12 SPN 3057 FMI 1 .............................................7-106

7.12.13 SPN 3057 FMI 2 .............................................7-108

7.12.14 SPN 3151 FMI 06 ............................................7-110

7.12.15 SPN 3151 FMI 07 ............................................7-113

7.12.16 SPN 3151 FMI 08 ............................................7-115

7.12.17 SPN 3151 FMI 09 ............................................7-118

7.12.18 SPN 3152 FMI 04 ............................................7-121

7.12.19 SPN 3156 FMI 08 ............................................7-124

7.12.20 SPN 3156 FMI 09 ............................................7-127

7.12.21 SPN 3351 FMI 21 ............................................7-130

7.12.22 SPN 3351 FMI 22 ............................................7-133

7.12.23 SPN 3352 FMI 21 ............................................7-136

7.12.24 SPN 3352 FMI 22 ............................................7-139

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8 Hydraulics ................................................................8-1

8.1 Hydraulic schematic ................................................8-3

8.1.1 Hydraulic schematic ..............................................8-5

8.2 Specifications ......................................................8-7

8.2.1 Power shuttle transmission specifications .............................8-10

8.3 Transmission oil cooler and lubrication .............................8-11

8.4 General service procedures ........................................8-13

8.4.1 Transmission oil ................................................8-13

8.4.2 Checking the transmission oil level ...................................8-13

8.4.3 Changing the transmission oil and filter ...............................8-13

8.5 Suction filter ......................................................8-15

8.5.1 Suction filter specifications ........................................8-15

8.5.2 Suction filter operation ............................................8-16

8.5.3 Suction filter maintenance .........................................8-16

8.6 Gear pump .......................................................8-17

8.6.1 Main pump ....................................................8-17

8.6.2 Sub pump .....................................................8-18

8.7 Cylinders .........................................................8-19

8.7.1 Power steering cylinder ...........................................8-19

8.7.2 Main cylinder ..................................................8-21

8.7.3 Main cylinder specifications ........................................8-23

8.7.4 Assist cylinder, if equipped ........................................8-23

8.8 Valves ............................................................8-25

8.8.1 Main relief valve ................................................8-25

8.8.2 Installing the main relief valve ......................................8-26

8.8.3 Main relief valve specifications ......................................8-26

8.8.4 Main control valve ...............................................8-27

8.8.5 Steering orbit roll ................................................8-28

8.8.6 Slow return valve ...............................................8-29

8.8.7 Assembling precautions for the slow return valve ........................8-30

8.8.8 Slow return valve specifications .....................................8-30

8.8.9 Safety valve ...................................................8-31

8.8.10 Assembling precautions for the safety valve ...........................8-31

8.8.11 Safety valve specifications ........................................8-31

8.8.12 Power takeoff control valve .......................................8-32

8.8.13 Assembling precautions for the power takeoff control valve ................8-33

8.8.14 Power takeoff control valve specifications .............................8-33

8.8.15 Reduce valve .................................................8-34

8.8.16 Assembling precautions for the reduce valve ..........................8-36

8.8.17 Reduce valve specifications .......................................8-37

8.8.18 Control valve ..................................................8-37

8.8.19 Assembling precautions for the control valve ..........................8-41

8.8.20 Control valve specifications .......................................8-41

8.8.21 High-low valve (P1 type only) ......................................8-42

8.8.22 Joystick valve (J type only) ........................................8-44

8.8.23 Joystick valve specifications .......................................8-48

8.8.24 Boom valve operation ...........................................8-49

8.8.25 Bucket valve operation ..........................................8-54

8.8.26 Remote control valve ............................................8-57

8.8.27 Remote control valve specifications .................................8-57

8.8.28 Removing the remote control valve .................................8-58

8.8.29 Remote control valve assembly ....................................8-58

8.8.30 Installing the remote control valve ..................................8-59

8.9 Parts and hydraulic diagrams ......................................8-60

8.9.1 Front loader adapter .............................................8-60

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Table of contents

8.9.2 External auxiliary hydraulics ........................................8-61

8.9.3 Hydraulic control linkage ..........................................8-62

8.9.4 Auxiliary hydraulic valves ..........................................8-65

8.9.5 Joystick link and lever ............................................8-67

8.9.6 Position control sensor and lever ....................................8-77

8.9.7 Adjusting the position control lever ...................................8-78

8.9.8 Three-point linkage ..............................................8-79

8.9.9 Three-point linkage specifications ....................................8-80

8.9.10 Drawbar .....................................................8-81

8.10 Hydraulic system troubleshooting ................................8-82

9 Index .................................................................Index-1

Appendix “A”

AGCO Power Engine Diagnostic fault codes and trees . . . . . . . . . . . . . . . . . . Appendix

4608 / 4609 / 4610 Service Manual
4283492M3

Table of contents

4608 / 4609 / 4610 Service Manual

4283492M3

Table of contents

1. Introduction

1.1 Introduction ............................................................1-3

1.1.1 The service manual ....................................................1-3

1.1.2 Replacement parts ....................................................1-3

1.1.3 Units of measurement ..................................................1-3

1.1.4 Machine identification ..................................................1-3

1.1.5 Serial number plate ....................................................1-4

1.1.6 Engine identification ...................................................1-4

1.1.7 Chassis number ......................................................1-5

1.2 Specifications ...........................................................1-6

1.2.1 Engine specifications ...................................................1-6

1.2.2 Electrical specifications .................................................1-6

1.2.3 Transmission specifications ..............................................1-7

1.2.4 Power takeoff specifications .............................................1-7

1.2.5 Front axle specifications ................................................1-7

1.2.6 Rear axle specifications .................................................1-8

1.2.7 Brake specifications ...................................................1-8

1.2.8 Hydraulic specifications .................................................1-8

1.2.9 Fuel specifications .....................................................1-8

1.2.10 Operating slope angle .................................................1-9

1.2.11 Lubrication specifications ...............................................1-9

1.2.12 Capacities .........................................................1-10

1.2.13 Maximum load capacity ...............................................1-10

1.2.14 Wheel bolt torque chart ...............................................1-11

1.2.15 Tire inflation pressures ................................................1-12

1.3 General dimensions ....................................................1-14

1.3.1 Platform tractor dimensions .............................................1-14

1.3.2 Cab tractor dimensions ................................................1-15

1.4 Lubrication / fill points .................................................1-17

1.4.1 Lubrication and maintenance chart ........................................1-17

1.4.2 Initial lubrication and maintenance chart ....................................1-18

1.4.3 Lubrication fill and drain locations .........................................1-19

1.5 General precautions for disassembly and installation .....................1-20

1.5.1 Precautions for disassembling and installing .................................1-20

1.5.2 Precautions when installing according to standards parts ........................1-20

1.6 Tightening torque chart ................................................1-23

1.7 Conversion table .......................................................1-25

4608 / 4609 / 4610 Service Manual 1-1
4283492M3

Table of contents

1-2 4608 / 4609 / 4610 Service Manual

4283492M3

1. Introduction

1.1 Introduction

1.1.1 The service manual

Read the table of contents and basic layout. Become familiar with all parts of this service manual. This
service manual gives the technician very important information.

Machine movement when in normal use determines right-hand and left-hand.
This manual covers general safety practices for this machine.
The photos, illustrations, and data used in this manual were current at the time of printing. Inline

production changes can make machines vary from the information in the service manual. The manufacturer
reserves the right to redesign and change the machine as necessary without notification.

WARNING:
In some of the illustrations and photos used in this manual, shields or guards may have
been removed for clarity. Never operate the machine with any shields or guards removed.
If the removal of shields or guards is necessary to make a repair, they must be replaced
before operation.

1.1.2 Replacement parts

To receive prompt efficient service, remember to have the following information:

Correct part description and part number
Model number of the machine
Serial number of the machine

1.1.3 Units of measurement

Measurements are given in metric units followed by the equivalent in US units. Hardware sizes are given
in millimeters for metric hardware and inches for US hardware.

1.1.4 Machine identification

Each machine is identified by a model and a serial number.
Record these numbers in the spaces given.
Give the model number and serial number to your dealer when parts or service are required.

Machine model number:

Machine serial number:

Date of delivery:

Dealer name:

Dealer address:

Dealer telephone number:

Dealer e-mail address:

Dealer fax number

4608 / 4609 / 4610 Service Manual 1-3
4283492M3

1. Introduction

1.1.5 Serial number plate

The serial number plate (1) is located below the
operator seat.

The serial number plate contains the model
number and serial number.

Fig. 1

1.1.6 Engine identification

The engine model number (1) is cast on the right­hand side of the engine block, below the injection
pump.

The engine serial number (2) is stamped into the
cylinder block, below the engine model number.

Engine model
number:

Engine serial
number:

Fig. 2

Fig. 3

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4283492M3

1.1.7 Chassis number

The chassis number (1) is stamped in right-hand
side of front frame.

Chassis number:

1. Introduction

Fig. 4

4608 / 4609 / 4610 Service Manual 1-5
4283492M3

1. Introduction

1.2 Specifications

1.2.1 Engine specifications

4608 4609 4610

Type Four stroke diesel engine
Model 33 AWIC
Make AGCO power
Number of cylinders 3
Aspiration Turbocharged and air to air intercooled
Injection Direct
Bore 108 mm
Stroke 120 mm
Displacement 3.3 L
Rated speed 2200 rpm
Low idle speed 912 to 988 rpm
High idle speed 2218 to 2402 rpm
Maximum torque at rpm 346 Nm at 1500 rpm 387 Nm at 1500 rpm 410 Nm at 1500 rpm
Engine horse power (Maximum

output)
Engine cooling Liquid, forced circulation
Air cleaner Dual stage, dry element
Air intake Engine cover grille
Cold starting aid Intake heater
Firing order 1-2-3
Valve clearance (cold) 0.35 mm

63 kW at 2000 rpm 71 kW at 2000 rpm 75 kW at 2000 rpm

1.2.2 Electrical specifications

4608 4609 4610

System voltage 12 volt
Grounding Negative
Battery cold cranking amperes

(cca) @ - 18 ºC

799 cca

Battery JIS type 130E41R

Battery case dimensions

Length 410 mm
Width 175 mm
Height 234 mm
Alternator 12 volt, 95 ampere
Starter 12 volt, 3.0 kW

1-6 4608 / 4609 / 4610 Service Manual

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1. Introduction

1.2.3 Transmission specifications

4608 4609 4610

Primary transmission Six speed synchronized
Range transmission Without creep gear, two speed sliding mesh

With creep gear, three speed sliding mesh

Mechanical shuttle Electro-hydraulic control with multi plate weet disc, 95% reverse

reduction

Gear speeds

Power shuttle Without creep gear, 12 forward, 12 reverse

With creep gear, 18 forward, 18 reverse

Clutch Multiple stage wet with 128 mm disc

1.2.4 Power takeoff specifications

4608 4609 4610

Type Independent, engine driven
Control Electro-hydraulic control
Clutch Hydraulically engaged, multi-plate wet disk
Output Clockwise rotation from the rear of the tractor

Shaft

540 rpm (North America only) 35 mm diameter, 6 spline, ISO type 1
1000 rpm (North America only) 35 mm diameter, 21 spline, ISO type 2
540/750 rpm (Australia) 35 mm diameter, 6 spline, ISO type 1

Engine speed

540 rpm 1993 rpm
1000 rpm (North America only) 2178 rpm
750 rpm (Australia only) 2129 rpm

1.2.5 Front axle specifications

4608 4609 4610

Engagement Mechanical
Joint on axle Bevel gear
Oscillation angle 6 to 8 degrees
Steering Hydrostatic
Rear wheel to front wheel drive

ratio

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4283492M3

1:1 .45 1:1 .4

1. Introduction

1.2.6 Rear axle specifications

4608 4609 4610

Final reduction Planetary

1.2.7 Brake specifications

4608 4609 4610

Type Wet multi disc
Actuation Mechanical
Braking area 467.36 sq cm (72.68 sq in) x 8 pieces
Parking brake Hook type

1.2.8 Hydraulic specifications

4608 4609 4610

Main hydraulic system

Pump Transmission mounted
Maximum output 66.5 l/min
Pressure 19.6 mPa

Steering system

Type Hydrostatic
Pump Transmission mounted
Maximum output 25.7 l/min
Pressure 15.8 mPa

Rear linkage

Type Three-point hitch
Size Category II
Control Single control lever

Lift capacity - measured at ball ends

Standard: 2500 kg
Optional: 3300 kg

Lift capacity - measured at 610 mm

Standard: 1500 kg
Optional: 2000 kg

1.2.9 Fuel specifications

4608 4609 4610

Type Ultra low sulfur fuel only
Above 4 °C No. 2-D
Below 4 °C No. 1-D

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1. Introduction

1.2.10 Operating slope angle

4608 4609 4610

Up/down 20 degrees
Side to side 20 degrees

1.2.11 Lubrication specifications

4608 4609 4610

Lubrication

Lubrication fittings Massey Ferguson M-1105 or equivalent lithium base grease No. 2
Engine oil Massey Ferguson Multiguard® or equivalent in the correct SAE

viscosity. Oil must meet or exceed MIL-L-46152 requirements, API

Service CJ-4, ACEA Service E7.

Engine oil viscosity

Transmission and differential
housing (including hydraulic
system)

Front axle AGCO Permatran® 821XL

Engine coolant

Freezing protection (original
factory fill)

Recommended coolant 50/50 mixture ethylene glycol and water

4608 / 4609 / 4610 Service Manual 1-9
4283492M3

AGCO Permatran® 821XL

-34 ºC

1. Introduction

1.2.12 Capacities

4608 4609 4610

Engine crankcase with filter 12.5 L
Cooling system 11 L
Fuel tank 105 L
Transmission and differential

housing (including hydraulic
system)

Front drive axle 8 L 10 L

58 L

1.2.13 Maximum load capacity

Four-wheel drive maximum load capacity

Model Ag tires 4608 4609 4610

Front 9.5-24 12.4-24 12.4-24
Rear 16.9-30 16.9-30 16.9-34

Platform tractors

Front axle weight

NA type 1150 kg 1200 kg
Aus type 1155 kg 1205 kg

Rear axle weight

NA type 1815 kg
Aus type 1835 kg

Total weight

NA type 2965 kg 3015 kg
Aus type 2990 kg 3040 kg

Cab tractor

Front axle weight

NA type 1250 kg 1300 kg
Aus type 1255 kg 1305 kg

Rear axle weight

NA type 1900 kg
Aus type 1920 kg

Total weight

NA type 3150 kg 3200 kg
Aus type 3175 kg 3225 kg

Maximum weight capacities

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4283492M3

1. Introduction

Model Ag tires 4608 4609 4610

Front 9.5-24 12.4-24 12.4-24
Rear 16.9-30 16.9-30 16.9-34

Front axle capacity 3400 kg 3800 kg
Rear axle capacity 4000 kg 4800 kg
Total capacity 5200 kg 6500 kg

NA = North American tractors
Aus = Australian tractors

NOTE:

The machines used to calculate the specifications above are equipped with a joystick. To calculate a
different total weight:

•

A machine without a joystick - subtract 60 kg

Two-wheel drive maximum load capacity

Model Tire 4608 4609 4610
Specifications

based on tire size

Platform tractors

Front axle weight 995 kg 1015 kg
Rear axle weight 1705 kg 1735 kg
Total weight 2700 kg 2750 kg

Cab Tractors

Front axle weight 1065 kg 1085 kg
Rear axle weight 1835 kg 1865 kg
Total weight 2900 kg 2950 kg

Maximum weight capacities

Front axle capacity 3400 kg 3800 kg
Rear axle capacity 4000 kg 4800 kg
Total capacity 5200 kg 6500 kg

NOTE:

The machines used to calculate the specifications above are equipped with a joystick. To calculate a
different total weight:

Front 7.5-16 7.5-18 7.5-18
Rear 16.9-30 18.4-30 18.4-30

•

A machine without a joystick - subtract 60 kg

1.2.14 Wheel bolt torque chart

Wheel bolts Torque

Front wheel lug nut 285 Nm
Rear wheel lug nut 285 Nm
Rear wheel center to

rim bolts (Ag and
industrial tires only)

4608 / 4609 / 4610 Service Manual 1-11
4283492M3

230 Nm

1. Introduction

1.2.15 Tire inflation pressures

Four-wheel drive

Model Tire

type

4608 AG Front 9.5-24 207 kPa

R4 Front 10.5/80-18 228 kPa

4609
4610

4610 low profile AG Front 12.5/80-18 317 kPa

AG Front 11.2-24 248 kPa

R4 Front 12.5/80-18 317 kPa

Tire location Tire size Pressure

Rear 16.9-30 124 kPa

Rear 19.5L-24 165 kPa

Rear 16.9-30 124 kPa
Front 12.4-24 221 kPa
Rear 18.4-30 110 kPa
Front 12.4-24 221 kPa
Rear 16.9-34 165 kPa

Rear 19.5L-24 164 kPa

Rear 16.9-24 124 kPa
Front 9.5-24 207 kPa
Rear 18.4-26 110 kPa

Two-wheel drive

Model Tire

Type

4608 AG Front 7.5-16 303 kPa

4609
4610

AG Front 9.5L-15 310 kPa

Tire Location Tire Size Pressure

Rear 16.9-30 124 kPa
Front 9.5-15 310 kPa
Rear 16.9-30 124 kPa

Rear 16.9-30 124 kPa
Front 7.5-18 303 kPa
Rear 16.9-30 124 kPa
Front 10-16 221 kPa
Rear 18.4-30 110 kPa
Front 10-16 221 kPa
Rear 16.9-34 165 kPa

The maximum tire pressures for maximum loads are given. Tire pressure can be reduced as the load on
the tire is reduced.

1-12 4608 / 4609 / 4610 Service Manual

4283492M3

1. Introduction

Tire pressures vary according to make, load, and speed as well as to the type of work being carried out.
Refer to the inflation tables issued by the tire manufacturers.

4608 / 4609 / 4610 Service Manual 1-13
4283492M3

1. Introduction

1.3 General dimensions

1.3.1 Platform tractor dimensions

Fig. 5

Four-wheel drive model dimensions

General
dimensions

Specifications
based on tire size

A Overall height 2650 mm 2710 mm 2624 mm
B Overall length

(front grille to
end of the three-

point hitch
C Minimum width 2045 mm 2050 mm 2002 mm
D Wheelbase 2260 mm
Ground clearance 460 mm 470 mm 343 mm
Front wheel tread 1450 mm 1610 mm
Rear wheel tread 1550 mm 1542 mm
Turning radius (with brake) 3300 mm
Weight NA 2965 kg 3015 kg 3105 kg

Tires 4608 4609 4610 standard 4610 low

profile
Front 9.5-24 12.4-24 12.4-24 12.5-80/18
Rear 16.9-30 16.9-30 16.9-34 16.9-24

NA 3815 mm 3875 mm 3792 mm
Aus 3895 mm 3955 mm

Aus 2960 kg 3040 kg

NA = North American tractors / Aus = Australian tractors
Two-wheel drive model dimensions

1-14 4608 / 4609 / 4610 Service Manual

4283492M3

1. Introduction

General dimensions Tires 4608 4609 4610 standard
Specifications based

on tire size

Front 9.5-24 12.4-24 12.4-24
Rear 16.9-30 16.9-30 16.9-34

A Overall height 2650 mm 2710 mm
B Overall length (front grille to end

3825 mm 3845 mm 3865 mm

of the three-point hitch
C Minimum width 2000 mm
D Wheelbase 2250 mm
Ground clearance 555 mm
Front wheel tread 1543 mm

1643 mm
1743 mm
1843 mm

Rear wheel tread 1176 to 1855 mm

1144 to 1854 mm (45 to 73 in)

(46.3 to 73 in)
Turning radius (with brake) 3300 mm
Weight 2700 kg 2750 kg

NA = North American tractors / Aus = Australian tractors

1.3.2 Cab tractor dimensions

Fig. 6

Four-wheel drive dimensions

4608 / 4609 / 4610 Service Manual 1-15
4283492M3

1. Introduction

General Dimensions Tires 4608 4609 4610
Specifications based

on tire size

Front 9.5-24 12.4-24 12.4-24
Rear 16.9-30 16.9-30 16.9-34

A Overall Height 2550 mm 2600 mm
B Overall Length (front

grill to end of three­point)

NA 3815 mm 3875 mm
Aus 3895 mm 3955 mm

C Minimum Width 2045 mm 2050 mm
D Wheelbase 2260 mm
Ground Clearance 460 mm 470 mm
Front Wheel Tread 1450 mm
Rear Wheel Tread 1550 mm
Turning Radius (with brake) 3300 mm
Weight NA 3150 kg 3200 kg

Aus 3175 kg 3225 kg

NA = North American tractors / Aus = Australian tractors
Two-wheel drive dimensions

General Dimensions Tires 4608 4609 4610
Specifications based

on tire size

Front 7.5-16 7.5-18 7.5-18
Rear 16.9-30 18.4-30 18.4-30

A Overall Height 2550 mm 2600 mm
B Overall Length (front

grill to end of three­point)

NA 3825 mm 3845 mm 3865 mm
Aus 3895 mm 3955 mm

C Minimum Width 2000 mm
D Wheelbase 2250 mm
Ground Clearance 555 mm
Front Wheel Tread 1543 mm

1643 mm
1743 mm
1843 mm

Rear Wheel Tread 1176 to 1855 mm

1144 to 1854 mm (45 to 73 in)

(46.3 to 73 in)
Turning Radius (with brake) 3300 mm
Weight 2900 kg 2950 kg

NA = North American tractors / Aus = Australian tractors

1-16 4608 / 4609 / 4610 Service Manual

4283492M3

1.4 Lubrication / fill points

1.4.1 Lubrication and maintenance chart

Severe conditions or conditions that are not normal will require more frequent lubrication.
See the machine specifications for correct type and quantity of lubricant.

Daily 100 hours 200 hours Other

X Check the engine oil level, fill if necessary.
X Check the transmission oil level, fill if

necessary.
X Clean the air cleaner element.
X Check the radiator coolant level, fill if

necessary.
X Inspect and clean the radiator fins.
X Inspect and clean the fuel filter sediment

bowl.
X Lubricate the lubrication fittings.

1. Introduction

X Inspect the windshield wiper, replace if

necessary.

Weekly Check the windshield washer fluid reservoir,

fill if necessary.
X X Inspect the air conditioner belt, replace if

necessary.
X X Inspect the engine belt, replace if

necessary.
X X Yearly Inspect the radiator hoses, replace if

necessary.
X X Inspect and correct the tire air pressure.
X X Inspect and tighten wheel bolts and nuts.

Weekly Drain water from the fuel prefilter.
X Drain moisture from the clutch housing.
X Yearly Inspect the power steering hoses, replace if

necessary.

X Yearly Inspect air conditioning hoses, replace if

necessary.

X Yearly Inspect the fuel hoses, replace if necessary.

X Check the front axle oil level, fill if

necessary.
X Inspect and adjust the brake pedal free play.
X Inspect the steering joint. If adjustment or

service is necessary, see your dealer.
X Inspect the toe in. If adjustment or service

is necessary, see your dealer.

4608 / 4609 / 4610 Service Manual 1-17
4283492M3

1. Introduction

Daily 100 hours 200 hours Other

X Inspect and tighten the tie rod end. If

X Clean the air conditioner condenser.

adjustment or service is necessary, see your
dealer.

Monthly Clean the air conditioner filter.
400 hours Change the engine oil and replace the filter.
400 hours Change the transmission oil and replace the

filter.
600 hours Replace the air filter element.
600 hours Change the front axle oil.

1000 hours Replace the fuel filter element. See your

dealer.

1000 hours Replace the engine belt.

First 500

hours, then

yearly
Yearly Inspect and replace the electrical wiring. If

Yearly Inspect the lamps, replace if necessary.
Yearly Inspect the warning device. If service is

Yearly Inspect rubber cab mounts, replace if

Yearly Inspect and the hydraulic hoses (joystick,

Yearly Inspect the assist cylinder hoses, replace if

Yearly Inspect the oil cooler hose, replace if

Yearly Drain, flush, and replace the radiator

1.4.2 Initial lubrication and maintenance chart

Inspect and adjust the engine valve

clearance. If adjustment or service is

necessary, see your dealer.

service is necessary, see your dealer.

necessary, see your dealer.

necessary.

hydraulic pump), replace if necessary.

necessary.

necessary.

coolant.

After first 50 hours

X Change the engine oil and replace the filter.
X Inspect the engine belt, replace if necessary.
X Change the transmission oil and replace the filter.
X Change the front axle oil.
X Inspect and adjust the brake pedal free play.
X Inspect and adjust the steering joint. If adjustment or service is necessary, see

your dealer.

X Inspect and adjust the toe in. If adjustment or service is necessary, see your

dealer.

1-18 4608 / 4609 / 4610 Service Manual

4283492M3

After first 50 hours

X Inspect and adjust the tie rod end. If adjustment or service is necessary, see

your dealer.
X Inspect and correct the tire air pressure.
X Inspect and adjust the wheel bolts and nuts.
X Inspect the power steering hose, replace if necessary.
X Inspect the fuel hose, replace if necessary.
X Inspect the electrical wiring, replace if necessary.
X Inspect the lamps, replace if necessary.
X Inspect the warning device, replace if necessary.
X Inspect the air conditioner belt, replace if necessary.
X Clean the air conditioner condenser.

1.4.3 Lubrication fill and drain locations

Grease fittings
Fill location

1. Introduction

Drain location
Oil level check location

Ref Description Type

1 Engine Engine oil
2 Radiator overflow

Coolant

reservoir
3 Fuel tank Diesel fuel
4 Transmission

Hydraulic oil

housing
5 Front axle, four-

Hydraulic oil

wheel drive only
6 Axle pivots Grease
7 Front spindles Grease
8 Ball joint Grease
9 Front brake pivots Grease
10 Brake arm pivots Grease
11 Parking brake

Grease

pivots
12 Lift rod Grease
13 Top link Grease

4608 / 4609 / 4610 Service Manual 1-19
4283492M3

Fig. 7

1. Introduction

1.5 General precautions for disassembly and installation

1.5.1 Precautions for disassembling and installing

Before Operation

Always be safety conscious in selecting clothes to wear and correct tools to use.
Before disassembly, make sure that you become familiar with the assembled condition to assist in

assembly.
Keep parts, and tools in the correct order during operations.
When assembling disassembled parts, discard used gasket, O-rings, or oil seals and install new ones.
When lifting, tip only the front, or rear part of the tractor, make sure to wedge the grounded wheels.
When the tractor is jacked up, make sure to support the full tractor with a stand. Do not raise the tractor

with only a jack. This is a dangerously unstable procedure.

1.5.2 Precautions when installing according to standards parts

Bearings

Use an installer when installing a bearing in a housing by the outer race. The installer is specially designed
to push only the outer race and vice versa.

The installer must be designed to install the bearing on the shaft in a parallel position.
When installing a bearing which looks the same on both sides, install the face with the identification

number visible. Install all bearings in the transmission case with their identification number pointing
outward.

A bearing installed in a shaft or a hole with an inner seat, must be pushed in fully until seated.
Bearings must turn smoothly.

Oil seals

A oil seal installer must not deform the oil seals.
During installation, be careful not to damage the lips. Make sure that the bearing is pushed in parallel to the

shaft or hole.
Installed oil seals must have no turnover of the lips and no dislocation of the springs.
When a multi-lip seal is installed, the grooves between the lips must be filled with grease.
Use a lithium-based grease.
There must not be any oil or water leaks around the new seals.

O-rings

Coat O-rings with grease before installing.
Installed O-rings must not have any tension or twist.
Installed O-rings must keep correct tightness.

1-20 4608 / 4609 / 4610 Service Manual

4283492M3

Snap rings

Snap ring installers must be designed so as not to
permanently deform the snap rings (1).

Installed snap rings must be installed correctly in
the groove.

Be careful not to overload the snap ring to the
point that the snap ring is permanently deformed.

Install a snap ring as shown in the figure, with its
round edge turned toward the retained part. This
round edge is formed when the snap ring is
pressed out.

Spring (roll) pin

Spring pins must install tightly.
Spring pins must be installed so that the seams

point to the direction from which the load is
applied.

1. Introduction

Fig. 8

Fig. 9

Cotter pins

Correctly bend the cotter pins at the ends as
shown in the figure when installing.

Fig. 10

Bolts and Nuts

Special bolts are installed at some locations, so make sure not to interchange the special bolts with the
other bolts.

Use a torque wrench to tighten the bolts and nuts to their specified torque .
When locking the bolts or nuts with wire, take note in the winding direction to hold the bolt tight.

4608 / 4609 / 4610 Service Manual 1-21
4283492M3

1. Introduction

When locking the bolts or nuts with a tab lock washer, bend the tab against the hex, to give secure
locking.

When locking bolts and nuts with an adhesive apply the adhesive on the thread and tighten correctly.
Apply a sealant to parts which have any risk of oil leaks, such as stud bolts and treaded holes.
Tighten each lock nut tight.
See the tightening torque table in introduction section when tightening the bolts and nuts.

Grease fittings

After installation, fill each grease fitting with grease.
When installing 45° or 90° grease fittings, make sure to turn the fitting in a direction that will let easy

access for a grease gun.

Other precautions

Make sure not to damage any finished surfaces or parts.
Always refrain from forcing installation.
Install each lever knob coated with an adhesive.
Coat each contact surface with an adhesive and tighten equally with bolts. Install adhesive coated surfaces

within 30 minutes after application of the adhesive.
The contact surface must be flawless and free from unwanted material. Remove all grease before

application of the adhesive.
Precautions for applying adhesives:

•

The surface or the thread where an adhesive is to be applied must be fully free of chips.

• The surface of the thread where an adhesive is to be applied must be fully free of oil.

1-22 4608 / 4609 / 4610 Service Manual

4283492M3

1.6 Tightening torque chart

1. Introduction

Main

components

Cylinder head Cylinder head 83.4 to 88.3 61.5 to 65.1 M11 X 1.5 18

Cylinder block Bearing cap 137.3 to 156.9 101.3 to 115.7 M14 X 1.5 10

Parts to be
tightened

Cylinder head
cover

rocker shaft 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 4
Injection nozzle 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 4
Fuel pipe 9.81 to 14.7 7.2 to 10.8 M8 X 1.25 4
Glow plug 14.7 to 19.6 10.8 to 14.5 M10 X 1.25 4
Glow plug

connector
Hanger 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 4

Front plate 13.7 to 23.5 10.1 to 17.3 M8 4
Thrust plate 5.85 to 9.85 4.3 to 7.3 M6 X 1.0 2
Rear plate 74.5 to 90.1 55.0 to 66.5 M12 X 1.5 8
Oil pan 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 24

Tightening torque Size Quantity
Nm lbf ft

9.8 to 19.6 7.2 to 14.5 M8 X 1.25 3

0.98 to 1.47 0.7 to 1.1 M4 X 0.7 4

Strainer clamp 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 1
Injection pump

cover

Crankshaft Connecting rod

cap
Flywheel 127.3 to 146.9 93.9 to 108.3 M14 X 1.5 8
Crankshaft

pulley
Gear case 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 16
Plug 7.9 to 17.7 5.8 to 13.0 M8 1
Oil pump 5.8 to 9.8 4.3 to 7.2 M6 X 1.0 3
Relief valve 14.7 to 24.5 10.8 to 18.1 M8 X 1.5 1
Adaptation unit 19.6 to 29.4 14.5 to 21.7 M16 X 1.5 1

Injection pump Injection pump 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 6

Connector 19.6 to 24.5 14.5 to 18.1 M12 X 1.5 1
Injection pipe 14.7 to 24.5 10.8 to 18.07 M12 X 1.5 8
Delivery valve

holder

5.85 to 9.85 4.3 to 7.3 M6 X 1.0 4

34.3 to 44.1 25.3 to 32.5 M9 X 1.0 8

166.7 to 203.9 123.0 to 150.4 M16 X 1.5 1

39.2 to 44.1 28.9 to 32.5 M18 X 1.5 4

Governor
weight bracket

Others Water pump 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 4

Thermostat
housing

4608 / 4609 / 4610 Service Manual 1-23
4283492M3

5.85 to 9.85 4.3 to 7.3 M6 X1.0 3

13.7 to 23.5 10.1 to 17.3 M8 X 1.25 2

1. Introduction

Main

components

Standard bolts
and nuts
torques

Parts to be
tightened

Water outlet

Tightening torque Size Quantity
Nm lbf ft

13.7 to 23.5 10.1 to 17.3 M8 X 1.25 2

pipe
Intake manifold 13.7 to 23.5 10.1 to 17.3 M8 X 1.25 8
Exhaust

13.7 to 23.5 10.1 to 17.3 M8 X 1.25 8

manifold
Cooling fan 5.85 to 9.85 4.3 to 7.3 M6 X 1.0 4
Starter motor 74.5 to 90.1 55.0 to 66.5 M12 X 1.25 2
Generator

34.3 to 46.1 25.3 to 34.0 M10 X 1.25 1

fulcrum
Generator

13.7 to 23.5 10.1 to 17.3 M8 X 1.25 1

adjusting plate
Solenoid 5.85 to 9.85 4.3 to 7.3 M6 X 1.0 2

5.89 to 9.87 4.3 to 7.3 M6 X 1.0

13.7 to 23.5 10.1 to 17.3 M8 X 1.25

34.3 to 46.1 25.3 to 34.0 M10 X 1.25

74.6 to 91.2 55.0 to 67.3 M12 X 1.25

1-24 4608 / 4609 / 4610 Service Manual

4283492M3

1.7 Conversion table

1. Introduction

Fig. 11

4608 / 4609 / 4610 Service Manual 1-25
4283492M3

1. Introduction

1-26 4608 / 4609 / 4610 Service Manual

4283492M3

Table of contents

2. Safety

2.1 Introduction ............................................................2-3

2.1.1 Safety alert symbol ....................................................2-3

2.1.2 Informational messages ................................................2-3

2.1.3 Safety messages .....................................................2-3

2.1.4 Safety signs .........................................................2-4

2.2 Operation .............................................................2-11

2.2.1 Prepare for operation ..................................................2-11

2.2.2 Roll over protective structure ............................................2-11

2.2.3 General information ...................................................2-11

2.2.4 Personal protective equipment ...........................................2-15

2.2.5 Seat instruction ......................................................2-15

2.2.6 Shield and guards ....................................................2-15

2.2.7 Power takeoff safety ..................................................2-16

2.2.8 Exhaust warning .....................................................2-17

2.2.9 Flying debris ........................................................2-17

2.3 Travel on public roads ..................................................2-18

2.4 Maintenance ...........................................................2-20

2.4.1 General maintenance information .........................................2-20

2.4.2 Fire prevention and first aid .............................................2-21

2.4.3 High pressure leaks ...................................................2-22

2.4.4 Engine safety .......................................................2-23

2.4.5 Fuel safety .........................................................2-24

2.4.6 Battery safety .......................................................2-25

2.4.7 Tire safety ..........................................................2-25

2.4.8 Replacement parts ...................................................2-26

4608 / 4609 / 4610 Service Manual 2-1
4283492M3

Table of contents

2-2 4608 / 4609 / 4610 Service Manual

4283492M3