New Holland T4020 Deluxe Tractor Service Repair Manual

T4020 Deluxe - T4020 Supersteer - T4030 Deluxe -

T4030 Supersteer - T4040 Deluxe - T4040 Supersteer -

T4050 Deluxe - T4050 Supersteer TRACTORS

SERVICE MANUAL

SECTIONS

GENERALGUIDELINES00 .....................................................

ENGINE10 ....................................................................

CLUTCH18 ....................................................................

TRANSMISSIONS21 ...........................................................

DRIVELINES23 ...............................................................

FRONTMECHANICALTRANSMISSION25 .......................................

REARMECHANICALTRANSMISSION27 ........................................

POWERTAKE-OFF31 .........................................................

BRAKES33 ....................................................................

HYDRAULICSYSTEMS35 ......................................................

STEERING41 ..................................................................

AXLEANDWHEELS44 .........................................................

CABAIRCONDITIONINGSYSTEM50 ...........................................

ELECTRICALSYSTEM55 .......................................................

PLATFORM,CAB,BODYWORK90 ..............................................

INTRODUCTORY NOTES

- This manual is divided into sections identified by two-figure numbers and each section has independent page numbering.

- The different sections can easily be found by consulting the table of contents on the following pages.

- The document number of the manual and the edition/update dates are given at the bottom of each page.

- Pages updated in the future will be identified by the same document number followed by an additional digit: first edition standard manual 87666787A - 1st update 87666787A1 - 2nd update 87666787A2 - etc. The update pages can replace or supplement the pages of the standard manual; the information necessary for the procedure for adding or replacing pages is given on the title page of the update. The publication will be completed with an appropriate index. If it is necessary to issue a new updated manual (2nd edition) it will have document number 87666787B, this indicates that the manual is composed of the standard version 87666787A completed with all the updates: 1st update 87666787A1 - 2nd update 87666787A2 - etc.

- The information contained in this manual was current on the date printed on each section. As NEW HOLLAND constantly improves its product range, some information may be out of date subsequent to modifications implemented for technical or commercial reasons, or to meet legal requirements in different countries.

In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.

IMPORTANT WARNINGS

- All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians, in strict accordance with the instructions given and using any specific tools necessary.

- Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.

- The Manufacturer and all organisations belonging to the Manufacturer's distribution network, including but not restricted to national, regional or local distributors, will accept no responsibility for personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer, including those used for maintenance and/or repair of the product manufactured or marketed by the Manufacturer.

In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any kind against personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer.

GENERALINSTRUCTIONS IMPORTANTNOTICE

AllmaintenanceandrepairworkdescribedinthismanualmustbeperformedexclusivelybyNEWHOLLAND servicetechnicians,instrictaccordancewiththeinstructionsgivenandusinganyspecifictoolsnecessary. Anyoneperformingtheoperationsdescribedhereinwithoutstrictlyfollowingtheinstructionsispersonally responsibleforanyeventualinjuryordamagetoproperty.

BATTERY

Beforecarryingoutanykindofserviceoperationdisconnectandisolatethebatterynegativelead,unless otherwiserequestedforspecificoperations(e.g.:operationsthatrequiretheenginerunning).Oncethespecific operationhasbeencompleted,disconnecttheleadinordertocompletetheoperation.

SHIMMING

Foreachadjustmentoperation,selectadjustingshimsandmeasureindividuallyusingamicrometer,thenadd uptherecordervalues:Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,ortherated valueindicatedforeachonshim.

ROTATINGSHAFTSEALS

Forcorrectrotatingshaftsealinstallation,proceedasfollows:

--beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes;

--thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged;

--positionthesealinglipfacingthefluid;withhydrodynamiclips,takeintoconsiderationtheshaftrotation directionandpositionthegroovessothattheywilldeviatethefluidtowardstheinnersideoftheseal;

--smearthesealinglipwithathinlayeroflubricant(useoilratherthangrease)andfillthegapbetweenthe sealinglipandthedustlipondoublelipsealswithgrease;

--insertthesealinitsseatandpressdownusingaflatpunch;donottapthesealwithahammerormallet;

--whilstinsertingtheseal,checkthattheitisperpendiculartotheseat;oncesettled,makesurethatitmakes contactwiththethrustelement,ifrequired;

--topreventdamagingtheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.

O--RINGSEALS

LubricatetheO--RINGsealsbeforeinsertingthemintheseats,thiswillpreventthemfromoverturningand twisting,whichwouldjeopardisesealingefficiency.

SEALINGCOMPOUNDS

ApplyoneofthefollowingsealingcompoundsonthematingsurfacesmarkedwithanX:RTVSILMATE, RHODORSILCAF1orLOCTITEPLASTICGASKET.

Beforeapplyingthesealingcompound,preparethesurfacesasfollows:

--removeanyincrustationsusingawirebrush;

--thoroughlyde--greasethesurfacesusingoneofthefollowingcleaningagents:trichlorethylene,petrolora waterandsodasolution.

BEARINGS

Wheninstallingbearingsitisadvisedto:

--heatthebearingsto80 ÷ 90 0Cbeforefittingontheshafts;

--allowthebearingstocoolbeforeinstallingthemfromtheoutside.

87666787A --11--2007

SPRINGPINS

Whenfittingsplitsocketelasticpins,ensurethatthepinnotchispositionedinthedirectionoftheforcerequired tostressthepin.

Spiralspringpinsdonotrequirespecialpositioning

SPAREPARTS

Usegenuinepartsonly.

Onlygenuinesparepartsguaranteethesamequality,durationandsafetyastheyarethesamepartsthatare assembledduringproduction.

Only genuineparts canofferthisguarantee.

Whenorderingspareparts,alwaysprovidethefollowinginformation:

--tractormodel(commercialname)andframenumber;

--enginetypeandnumber;

--partnumberoftheorderedpart,whichcanbefoundinthe”Microfiches”orthe”SparePartsCatalogue”,used fororderprocessing.

NOTESFOREQUIPMENT

ThetoolsthatNEWHOLLANDproposeandillustrateinthismanualare:

--specificallyresearchedanddesignedforusewithNEWHOLLANDvehicles;

--necessarytomakereliablerepair;

--accuratelybuiltandstrictlytestedtoofferefficientandlong--lastingworkingmeans.

Byusingthesetools,repairpersonnelwillbenefitfrom:

--operatinginoptimaltechnicalconditions;

--obtainingthebestresults;

--savingtimeandeffort;

--workinginsafeconditions.

IMPORTANTNOTES

Wearlimitvaluesindicatedforcertainpartsarerecommended,butnotbinding.Theterms”front”,”rear”, ”right--hand”and”left--hand”(whenreferredtodifferentparts)areintendedasseenfromthedrivingpositionwith thetractorinthenormaldirectionofmovement.

MOVINGTHETRACTORWITHTHEBATTERYREMOVED

Externalpowersupplycablesshouldonlybeconnectedtotherespectivepositiveandnegativecableterminals, usingefficientclampsthatguaranteeadequateandsecurecontact.

Disconnectallservices(lights,windshieldwipers,etc.)beforestartingthevehicle. Ifthevehicleelectricalsystemrequireschecking,carryoutoperationswiththepowersupplyconnected;once checkingiscompleted,disconnectallservicesandswitchoffthepowersupplybeforedisconnectingthecables.

87666787A --11--2007

SAFETYREGULATIONS

WARNINGANDDANGERSYMBOL

Thiswarningsymbolpointsoutimportantmessages concerningyoursafety.

Carefullyreadthefollowingsafetyregulationsand observeadvisedprecautionsinordertoavoid potentialhazardsandsafeguardyourhealthand safety.

Inthismanualthesymbolisaccompaniedbythe followingkey--words:

WARNING --Warningsconcerningunsuitablerepair operationsthatmayjeopardisethesafetyofRepair personnel.

DANGER --Specificwarningsconcerningpotential hazardsforoperatorsafetyorforotherpersons directlyorindirectlyinvolved.

TOPREVENT ACCIDENTS

Mostaccidentsorinjuriesthatoccurinworkshops aretheresultofnon--observanceofsimpleand fundamentalsafetyregulations.Forthisreason,IN MOSTCASESTHESEACCIDENTSCANBE AVOIDED:byforeseeingpossiblecausesand consequentlyactingwiththenecessarycautionand care.

Accidentsmayoccurwithalltypesofvehicle, regardlessofhowwellitwasdesignedandbuilt. Acarefulandjudiciousservicetechnicianisthebest guaranteeagainstaccidents.

Preciseobservanceofthemostbasicsafetyruleis normallysufficienttoavoidmanyseriousaccidents.

DANGER. Nevercarryoutanycleaning,lubrication ormaintenanceoperationswhentheengineis running.

SAFETYREGULATIONS

GENERAL

--Carefullyfollowspecifiedrepairand maintenanceprocedures.

--Donotwearrings,wristwatches,jewellery, unbuttonedorloosearticlesofclothingsuchas: ties,tornclothing,scarves,openjacketsorshirts withopenzipsthatmayremainentangledin movingparts.Itisadvisedtowearapproved safetyclothing,e.g.:non--slipfootwear,gloves, safetygoggles,helmets,etc.

--Donotcarryoutrepairoperationswithsomeone sittinginthedriver’sseat,unlessthepersonisa trainedtechnicianwhoisassistingwiththe operationinquestion.

--Donotoperatethevehicleoruseanyofthe implementsfromdifferentpositions,otherthan thedriver’sseat.

--Donotcarryoutoperationsonthevehiclewith theenginerunning,unlessspecificallyindicated.

--Stoptheengineandensurethatallpressureis relievedfromhydrauliccircuitsbeforeremoving caps,covers,valves,etc.

--Allrepairandmaintenanceoperationsmustbe carriedoutusingextremecareandattention.

--Servicestepsandplatformsusedinaworkshop orinthefieldshouldbebuiltincompliancewith thesafetyrulesinforce.

--Disconnectthebatteriesandlabelallcontrolsto indicatethatthevehicleisbeingserviced.Block themachineandallequipmentwhichshouldbe raised.

--Donotcheckorfillfueltanks,accumulator batteries,norusestartingliquidwhensmokingor nearnakedflames,asthesefluidsare inflammable.

--Brakesareinoperativewhenmanuallyreleased forrepairormaintenancepurposes:Useblocks orsimilardevicestocontrolthemachineinthese conditions.

--Thefuelnozzleshouldalwaysbeincontactwith thefillingaperture:Maintainthiscontactuntilthe fuelstopsflowingintothetanktoavoidpossible sparksduetostaticelectricitybuild--up.

GENERALSPECIFICATIONS

Engine,technicaltype:

--ModelT4040typeF4CE9484N*J601(BOSCHpump) ....

--ModelT4050--typeF4CE9484M*J601(BOSCHpump)..

Totaldisplacement...................................... 4485cm3

Compressionratio...................................... 16.5:1

MaximumPowerOutput:

--ModelT4040--typeF4CE9484N*J601 63kW(86Hp)

--ModelT4050--typeF4CE0454C*D600/*D603 71kW(97Hp)

Maximumpowerspeed 2300rpm

--Maximumtorque:ModelT4040--typeF4CE9484N*J601. 370Nm

--Maximumtorque:ModelT4050--typeF4CE9484M*J601 418Nm

Maximumtorquespeed 1300rpm

87666787A --11--2007

Op.1000110

ENGINERemoval--Installation

DANGER

Liftandhandleallheavypartsusingsuitablelifting equipment.

Makesurethatassembliesorpartsaresupportedby meansofsuitableslingsandhooks.Ensurethat no--oneisinthevicinityoftheloadtobelifted.

ATTENTION

Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.

1.Removethebonnetasdescribedinoperation 9010022

2.Extractthefixingpinandremovetheballast(1); unscrewtheretainingscrewsandretrievethe ballastsupport(2).

3.IfthetractorisaT4040SupersteerorT4050 Supersteermodel,positionandsecurethe bracket 380001613 (1)togetherwiththespacers 50162 (4)onthefrontaxle(3)andassociated support(2).

4.Unscrewtheretainingboltsandremovetheside grille(1). Performthisoperationontheothersideofthe tractortoo.

87666787A --11--2007

5.Unscrewtherelatedretainingboltandloosenthe guide(1),unhookthecatchandtakeoutthe condenser(2).

6.Disconnecttheelectricalconnectionfromthe compressor(1)andunscrewtherelated retainingbolts.

Removethebracketsfixingthepipesoftheair conditioningsystemandtakethecondenser, compressorandpipesunderthetransmission withoutdisconnectingthepipes.

7.Unscrewthebolts(3)securingtheexhaustpipe (1),unscrewtheexhaustsilencerretainingbolts (2)andremovetheentireassembly. Unscrewtheretainingboltsandremovetheheat shield.

8.Removetheguard(1)anddisconnectthecables fromthestartermotor(2).

9.Disconnectthepipes(1)ofthecabheating systemanddraintheenginecoolingsystem.

10.Unscrewthepluganddraintheoilfromtherear transmissioncasing(theprescribedquantityis 42litres).

11.Disconnectthepowersteeringpipes(2), unscrewtherelatedretainingboltsandremove thebracket(1).

12.Disconnecttheelectricalconnectionfromthe brakefluidreservoir(1),unscrewtheretaining boltsandremovethereservoirfromthe supportingbracket.

13.Unscrewtheretainingboltsandremovethe bonnetbracket(1).

14.Disconnect:themainelectricalconnections(1), theconnectionofthesteeringsensorandthecab ground,disconnectthethrottlecable(2)fromthe injectionpump.

15.Disconnectthedieselpipes(1)fromtheinjection pump. Disconnectthepipe(2)fromthepump.

16.Disconnect:thetransmissionoilcoolerpipes(1) andthefrontaxledifferentiallockpipe(2).

87666787A --11--2007

17.IfthetractorisaT4040SupersteerorT4050 Supersteermodel,unscrewthefrontandrear retainingbolts,unscrewthefrontpivotpin retainingscrewandremovethebracket(1). Unscrewtherelativeretainingboltsandremove therearguard.

18.IfthetractorisaT4040DeluxeorT4050Deluxe model,unscrewthefront,centralandrear retainingboltsandremovetheguardonthe propellershafts(1).

19.Removethecirclip(2)andmovethefrontsleeve (1)backwardsinordertofreeitfromthegroove onthefrontaxle.

20.Removethecirclip(2)andmovetherearsleeve (1)inordertoreleaseitfromthegrooveonthe drive.

21.Removethepropellershaftcentralsupport(1) retainingboltsandextracttheshafttogetherwith thesupport.

22.Loosentheretainingboltandturnthebracket(1) through90°

23.Formodelsfittedwithbrakesonthefrontaxleit isnecessarytodrainthebrakefluidtankand disconnectthepipes(1,2and3)fromtheblock.

24.Unscrew:theretainingboltsofthepipe(1) deliveringoiltothepumpandtheboltsretaining thepipe(2)tothefiltersupport.

25.Loosentherelatedclampsandremovethe sleeve(2)fromthepipe(1)andremovethe transmissionoilinletpipetogetherwiththe above--mentionedsleeve.

26.Unscrewtheretainingboltsandremovethe guard(1).Dothisonbothsides.

27.Unscrewtheretainingboltsandremovethecab matguard(2). Removetheplasticpedal(1).

28.Unscrewthebolts(1)(onbothsides),extractthe springpin(2)andremovethethrottlepedal(3).

87666787A --11--2007

29.Raisethefrontpartofthecabmat;removethe twoplasticplugsand,throughthehole(1), unscrewthefourupperboltssecuringtheengine totheclutchcasing.

30.Placeastandundertheclutchcasing,attachthe rearportionoftheenginetoahoist,usingchains (1).

31.Unscrewtheremainingbolts(1)securingthe enginetotheclutchcasingandseparatethe enginewiththefrontaxlefromtheclutchcasing.

32.Disconnecttheconnections(1)fromtheclogged airfiltersensor.

33.Placeastandundertherearportionofthebevel drivecasing(T4040SupersteerorT4050 Supersteer)ortwostands:oneundertheaxle supportattherearandtheotherunderthefront side.(modelswithstandardfrontaxle). Keepingthechains(1,fig.34)connected,join onechain(5)tothefrontoftheengine. Unscrewtheclampsandremove:theengineoil vapourrecirculationpipe(3),turbochargerintake pipe(2),andtheintakeaircoolerpipes(1and4).

34.Disconnectthelower(1)anduppersleevesfrom theradiator,removethebracket(2)fasteningthe powersteeringpipe.

35.FortheT4040DeluxeorT4050Deluxemodels, insertawoodenwedgeoneachsidebetweenthe axlesupportandtheaxleitself. Forallmodels,unscrewthebolts(1)onboth sidesandseparatetheenginefromthe axle--supportassemblywiththeradiatorand battery.

36.Resttheengineonanadequatesupport.

37.Tore--fittheengine,proceedasfollows.

ATTENTION

87666787A --11--2007

--Refittheenginetotheaxle--supportassembly withtheradiator,battery,coolers:intakeairand transmissionoil.

--Connecttheupperandlowersleevesofthe radiatortotheengine.

--Securethepowersteeringpipes.

--Beforerefittingtheenginetotheclutchbox carefullycleanthematingsurfacesandapply sealingcompound(2mmdiameter),according tothediagramshownSection21,Chapter1, page30.

--Positiontheengineontheclutchcasingand secureitwiththespecificbolts.

--Fittheplasticplugsonthecabfloor.

--Movethecabmatintotherightpositionand secureitwiththetwoboltsontheupright(dothis onbothsides).

--Fitthethrottlepedalwiththeplasticpart.

--Positionandsecuretheguardofthecabmat(do thisonbothsides).

--Fitthetwolowerguardsofthecontrolpanel(do thisonbothsides).

--Position,connectandsecuretheoildeliverypipe tothelift.

--Position,connectandsecuretheliftcontrol pumpoilinletpipe.

--Formodelsfittedwithbrakesonthefrontaxleit isnecessarytoconnectthepipestotherelated block.

--Positionandsecurethebracketbetweenthe clutchhousingandengine.

--Positionthepropellershaft,securethecentral support,slidethetwofrontandrearsleevesand securethemwiththecirclips.

--IfthetractorisaT4040DeluxeorT4050Deluxe model,positionthepropellershaftguardand secureit.

--IfthetractorisaT4040SupersteerorT4050 Supersteermodel,positionthepropellershaft rearguardandsecureit.

--IfthetractorisaT4040SupersteerorT4050 Supersteermodel,positionthepropellershaft frontguardandsecureit.

--IfthetractorisaT4040SupersteerorT4050 Supersteermodel,unscrewtheretainingbolts andremovethebracket 380001613 withthe spacers 50612.

--Connectthedifferentiallockcontrolpipe.

--Connectthepipestothetransmissionoilcooler pipes.

--Connectthefuelsupplyandreturnlinestothe injectionpump.

--Connectthedeliverypipetothepowersteering pump.

--Connectalltheelectricalconnectionsbetween thecabandengine.

--Positionandsecurethegroundcablebetween thecabandengine.

--Positionandsecurethethrottlecontrolrod.

--Positiontheupperenginebracketwiththeheat guardandsecureit.

--Connectthefrontpipestotherearpipes deliveringcoolanttothecabheater.

--Positionandsecurethebrakefluidtankand connecttheelectricalconnectiontothe above--mentionedpart.

--Connectthesteeringcontrolpipes.

--Connecttheelectriccabletothestartermotor andfittherelevantprotection.

--Positionandsecuretheheatshield,exhaust silencertotheengineandtothecab.

--Positionandsecure:thecompressor,condenser andrelatedpipes.

--Connecttheelectricalconnectiontothe compressor.

--Positionandsecurethesidegrille(dothison bothsides).

--Secure:theradiatorfixingbracket,engineoil vapourrecirculationpipe,inletpipeandintakeair coolerpipes.

--Connectthecloggedairfiltersensorpressure switchandsteeringsensorconnections.

--Formodelsfittedwithbrakesonthefrontaxleit isnecessarytofilltherelevanttank(seesect.00, page6fortheprescribedproductandquantity) andbleedthebrakingsystem(seesect.33).

87666787A --11--2007

--Screwtheplugonthereartransmissioncasing andfillupwithoil(seesect.00,page6forthe prescribedproductandquantity).

--Filluptheenginecoolingsystem(seesect.00, page6fortheprescribedproductandquantity).

--Positionandsecuretheballastsupport.

--Positionandsecuretheballast.

--Installthebonnetasdescribedinoperation 9010022

87666787A --11--2007

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Op.1000154 ENGINEDisassembly--Assembly

ThefiguresrefertotheF4CE9484M*J601versions of71kW(97hp)mod.T4050.Therevisionisto highlightanddescribethespecificpartsofthe versionsF4CE9484N*J601of63kW(86hp)mod. T4040andtheirrespectivevariants.

ATTENTION

Handleallpartscarefully.Donotputyourhandsor fingersbetweenparts.Weartheprescribedsafety clothing,includinggoggles,glovesandsafety footwear.

1.Removetheengineasdescribedinoperation 1000110,proceedasfollows.

2.Drainofftheengineoilbyremovingtheplugfrom thesumpandtheoilfillerplug.

3.Detachthefanunitfromthefanpulley.

4.Tobeabletofitthebracket 380000661 (forfixing theenginetotheoverhaulstand)tothe crankcase,itisnecessarytoremovethewiring (1)fromtheleft--handsideoftheengine.

5.Tobeabletofitthebracket 380000661 tothe crankcaseontheright--handside,removethe startermotor(5),oilfilter(3),clamp(4),and turbineoilreturnpipe(1).

6.Fixthegearboxtotherotatingstand 380000301 Detachtheoildeliverypipe(2).

7.Removetheintakemanifold(2).

8.Disconnecttheengineoilvapourrecoverypipe fromtheblow--by(3).

9.Removethetappetcovers(1).

10.Removethepipeswiththequick--fitcoupling(6) and(8).

11.RemovethepipingfromtheLDAsystem(5).

12.Removethefuelfilter(7).

13.Removetheheater(4).

14.Removethecontrolunitfortheheater(10).

15.Removethefuelfiltersupport(9).

16.Removetheinjectorfeedpipe(4)fromthe injectionpump(3).

17.Removethebracketsonthecylinderheadofthe pipeassembly(1),(2)and(6).

18.Replacefuelsupplypump(5).

19.Detachthefuelpipeassembly(1)fromthe injectors.

20.Removethefueloutletpipe(2)fromtheinjectors removingthescrew(3)andtheseal(4).

87666787A --11--2007

21.Removethescrews(2)andtheturbine(1).

22.Removetheexhaustmanifold(3).

23.Removethebelt(3,fig.46)oftheauxiliary membersbylooseningthetightener.

24.Removethealternator(6),fanpulley(2)andthe tightener(8).Removethesupport(1)ofthe pulley(2)andtheoilcooler(7).

25.Removethecoolantpump(5).

26.Removetheenginecoolingsystemfitting(4) fromthecrankcase.

NOTE: Thecoolantpump(5)cannotbeoverhauled. Itmustbereplacedifthereisanyirregularoperation.

27.Locktheflywheeltostopitturning,removethe fixingscrews(1)fromthepulley(2).

Removingthecrankshaftfrontseal (Op.28. ÷ 32.)

28.Applytool 380000665 (4)onthefronttang(2)of thecrankshaft.

29.Perforatetheinnerseal(1)withadrillbit ( ∅ 3.5mm)throughtheguideholesofthetool 380000665 (4),foradepthof5mm.

30.Securethetool 380000665 (4)totheseal(1)with thescrews(3)provided.

31.Extracttheseal(1)byscrewingdownthescrew (5).

32.Fitthetierod(3)ofthetool 380000669 tothe outerseal(1)asshowninthefigure49andwith thelever(4),extractitfromthefrontcover(2).

33.Turntheengineover,takeoutthescrews(2)and removetheoilsump(1).

34.Takeoutthescrews(2)andremovetheoilpump (1).

NOTE: Theoilpump(1)cannotbeoverhauled. Itmustbereplacedifthereisanyirregularoperation.

35.Usingthepin(1),locktheadditional counterweights(2)attheT.D.C. Unscrewtheretainingbolts(3)andremovethe additionalcounterweights(2).

87666787A --11--2007

MIF1113A

36.Beforeremovingtheinjectionpump,dothe timingandlocktheengineflywheelwithcylinder no.1atT.D.C.asindicatedonpage8,using tools 380000988 and 380000732.Thenloosen thebolt(2),removethe“L”spacer(1)andlock thescrew(2)inordertokeepthepumpintime withtheengineflywheel.

NOTE: Keepthe”L”spacerwiththepumpcasing.

37.Removethethreenuts(2)(3)(5)securingthe injectionpump(1)tothecrankcase(4)and extractitfromitshousing.

38.Removethescrews(2)fixingtheengineflywheel (1)tothecrankshaft.

39.Screwtwopins(2)oftheappropriatelengthinto theholesinthecrankshaft(3).

40.Extracttheengineflywheel(1)soitcanbeslung withtheliftandputitawayinaspecificcontainer.

Removingthecrankshaftrearseal (Op.41.÷ 44.)

41.Extracttheseal,fittingthetool 380000663 (3)on therearshank(1)ofthecrankshaft.

42.Perforatetheinnerseal(5)withadrillbit ( ∅ ∅ 3.5mm)throughtheguideholesofthetool 380000663 (3),foradepthof5mm.

43.Securethetool 380000663 (3)totheseal(5)by screwingdownthescrews(2)supplied.

44.Extracttheseal(5)byscrewingdownthescrew (4).

45.Takeoutthescrews(2)andremovethetiming gearbox(1),retrievingtheinjectionpumpgear.

NOTE: Notedowntheassemblypositionofthe screws(2)astheyhavedifferentsizes.

46.Takeoutthescrews(1)andremovethegears(3) and(4)fromthecamshaft(2).

47.Takeoutthebolts(1)andremovethehydraulic pumpdrivegear(2).

87666787A --11--2007

48.Foreachcylinder,removetherockerarm assembly(1)loosentheadjusternuts(3), unscrewtheadjusters(4)andtakeoutthe screws(2).

NOTE: Afterremovingthecylinderhead,removethe brackets(1)and(2).

MIF0933A

49.Extracttheinjectors(2)withtool 380000671 (1).

MIF0934A

50.Takeoutthescrews(1)fixingtheheadtothe crankcase.

MIF1120A

51.Afterfittingthebrackets(1)and(2)hookthe metalcablesanddetachthecylinderheadfrom thecrankcasewiththehoist.

MIF1121A