New holland cr960 combine harvesters service repair manual

Print No. 604.64.971.00
NEW HOLLAND REPAIR
MANUALCR920
CR940
CR960
CR970
CR980

CR920 -- CR940 -- CR960 -- CR970
CR980
COMBINES
REPAIR MANUAL
SECTIONS
GENERAL INFORMATION
ENGINE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIVE PTO 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT MECHANICAL DRIVE 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDROSTATIC DRIVE 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES AND CONTROLS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEMS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOWING HOOKS & BALLASTING 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING AXLE 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION & TRACKS 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIMATE CONTROL 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT FEEDING 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THRESHING 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEPARATION 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING SYSTEM 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRAIN STORAGE 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATFORM, CAB, BODYWORK AND DECALS 90. . . . . . . . . . . . . . . . . . . . . .
S E R V I C E

GENERAL INFORMATION 1
604.64.971.00 -- 05 -- 2003
SECTION 00 - GENERAL INFORMATION
CONTENTS
Section Description Page
00 000 Foreword 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part and Accessories 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautionary Statements 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Considerations 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Considerations 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Considerations 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Considerations 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Antifreeze (See Fire, Solvents, i.e., Isopropanol, Ethylene Glycol, Methanol) 7. . . . . . . . . . . .
Battery Acids (See Acids and Alkalis) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake and Clutch Linings and Pads (See Legal Aspects) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brazing (See Welding) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chemical Materials - General (See Legal Aspects) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Linings and Pads (See Brake and Clutch Linings and Pads) 8. . . . . . . . . . . . . . . . . . . .
Corrosion Protection Materials (See Solvents, Fire) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting (See Welding) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dewaxing (See Solvents and Fuels - Kerosene) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dusts 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Shock 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Fumes 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fiber Insulation (See Dusts) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire (See Welding, Foams, Legal Aspects) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foams- Polyurethane (See Fire) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuels (See Fire, Legal Aspects, Chemicals - General, Solvents) 10. . . . . . . . . . . . . . . . . . . .
Gas Cylinders (See Fire) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Workshop Tools and Equipment 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Pressure Air, Lubrication and Oil Test Equipment 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Legal Aspects 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants and Greases 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paints (See Solvents and Chemical Materials - General) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solder (See Welding) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Identification 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque Data for Hydraulic Tubes and Fittings 18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe Thread Fitting Torque 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of ORFs (O-ring Flat Faced) Fittings 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealants 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 GENERAL INFORMATION
604.64.971.00 -- 05 -- 2003
FOREWORD
Appropriate service methods and correct repair
procedures are essential for the safe, reliable
operation of all equipment, as well as the personal
safety of the individual performing the repair.
This Repair Manual provides troubleshooting,
overhaul, and pressure-testing instructions using
recommended procedures and equipment. Follow-
ing these instructions will ensure the safe, efficient,
and timely completion of the service or repair.
There are numerous variations in procedures,
techniques, tools, and parts for servicing machines,
as well as in the skill of the individual doing the work.
This manual cannot possibly anticipate all such
variations and provide advice or cautions as to each.
Accordingly, anyone who departs from the instruc-
tions provided in this manual must first establish that
their personal safety, the safety of others, and the
integrity of the machine will not be compromised by
the choice of methods, tools or parts.
The manual is divided into sections which are
subdivided into chapters: Each chapter contains
information on general operating principles, detailed
inspection, overhaul and, where applicable, specific
troubleshooting, special tools, and specifications.
Any reference in this manual to right, left, rear, front,
top, or bottom is as viewed from the operator’s seat,
looking toward the normal direction of travel.
All data and illustrations in this manual are subject to
variations in build specification. This information was
correct at the time of issue, but New Holland policy
is one of continuous improvement, and, the right to
change specifications, equipment, or design at any
time, without notice, is reserved.
ABOUT IMPROVEMENTS
New Holland is continually striving to improve its
products. We must, therefore, reserve the right to
make improvements or changes when it becomes
practical and possible to do so, without incurring any
obligation to make changes or additions to the
equipment sold previously.
ALL SPECIFICATIONS ARE SUBJECT TO
CHANGE WITHOUT NOTICE.
PART AND ACCESSORIES
Genuine NEW HOLLAND parts and accessories
have been specifically designed for NEW HOLLAND
MACHINES.
We would like to point out that “NON GENUINE”
parts and accessories have not been examined and
released by NEW HOLLAND. The installation and or
use of such products could have a negative effect
upon the design characteristics of your machine and
thereby affect its safety. NEW HOLLAND is not liable
for any damage caused by the use of “NON
GENUINE” NEW HOLLAND parts and accessories.

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PRECAUTIONARY STATEMENTS
PERSONAL SAFETY
Throughout this manual and on machine decals, you
will find precautionary statements (“DANGER”,
“WARNING”, and “CAUTION”) followed by specific
instructions. These precautions are intended for the
personal safety of you and those working with you.
Please take the time to read them.
DANGER
This word “DANGER” indicates an immediate
hazardous situation that, if not avoided, will
result in death or serious injury. The color
associated with Danger is RED.
WARNING
This word “WARNING” indicates a potentially
hazardous situation that, if not avoided, could
result in death or serious injury. The color
associated with Warning is ORANGE.
CAUTION
This word “CAUTION” indicates a potentially
hazardous situation that, if not avoided, may
result in minor or moderate injury. It may also
used to alert against unsafe practices. The color
associated with Caution is YELLOW.
FAILURE TO FOLLOW THE “DANGER”,
“WARNING”, AND “CAUTION” INSTRUCTIONS
MAY RESULT IN SERIOUS BODILY INJURY OR
DEATH.
MACHINE SAFETY
The additional precautionary statement
(“IMPORTANT”) is followed by specific instructions.
This statement is intended for machine safety.
IMPORTANT: The word “IMPORTANT”is used to
inform the reader of something he needs to know to
prevent minor machine damage if a certain
procedure is not followed.
INFORMATION
NOTE: Instructions used to identify and present
supplementary information.
SAFETY PRECAUTIONS
Practically all service work involves the need to drive
the combine. The operator’s manual, supplied with
each combine, contains detailed safety precautions
relating to driving, operating, and servicing the
combine. These precautions are as applicable to the
service technician as they are to the operator and
should be read, understood and practiced by all
personnel.
Prior to undertaking any maintenance, repair,
overhaul, dismantling or reassembly operations,
whether within a workshop facility or in the field,
consideration should be given to factors that may
have an effect upon safety, not only upon the
mechanic carrying out the work, but also upon
bystanders.
PERSONAL CONSIDERATIONS
The wrong clothes or carelessness in dress can
cause accidents. Be sure to wear suitable clothing
when servicing equipment.
Some jobs require special protective equipment; be
sure to use protective equipment when required.
Skin Protection
Used motor oil may cause skin cancer. Follow work
practices that minimize the amount of skin exposed
and length of time used oil stays on your skin.
Eye Protection
The smallest eye injury may cause loss of vision.
Injury can be avoided by wearing eye protection
when engaged in chiselling, grinding, discing,
welding, and painting.
Breathing Protection
Fumes, dust, and paint spray are unpleasant and
harmful. These can be avoided by wearing
respiratory protection.
Hearing Protection
Loud noise may damage your hearing, and the
greater the exposure the worse the damage. If the
noise is excessive, wear ear protection.
Lifting Protection
Avoid injury by correctly handling components. Make
sure you are capable of lifting the object. If in doubt
get help.

604.64.971.00 -- 05 -- 2003
Hand Protection
It is advisable to use a protective cream before work
to prevent irritation and skin contamination. After
work clean your hands with soap and water. Solvents
such as mineral spirit and kerosene may harm the
skin.
Foot Protection
Substantial or protective foot wear with reinforced
toe caps will protect your feet from falling objects.
Additionally, oil-resistant soles will help to avoid
slipping.
Special Clothing
For certain work it may be necessary to wear flame
or acid-resistant clothing.
EQUIPMENT CONSIDERATIONS
Machine Guards
Before using any machine, check to ensure that the
machine guards are in position and serviceable.
These guards not only prevent parts of the body or
clothing coming in contact with the moving parts of
the machine, but also ward off objects that might fly
off the machine and cause injury.
Lifting Devices
Always ensure that lifting equipment, such as chains,
slings, lifting brackets, hooks and eyes, are
thoroughly checked and in good condition before
use. If in doubt of weight capacity, select stronger
equipment than is necessary.
Never stand under a suspended load or raised
implement.
Compressed Air
The pressure from a compressed-air line often
exceeds 100 PSI (690 kPa). It is perfectly safe if used
correctly. Any misuse may cause injury.
Never use compressed air to blow dust, filing, and dirt
away from your work area unless the correct type of
nozzle is fitted.
Compressed air is not a cleaning agent; it will only
move dust from one place to another. Look around
before using an air hose as bystanders may get grit
into their eyes, ears, or skin.
Hand Tools
Many cuts, abrasions and injuries are caused by
defective tools. Never use the wrong tool for the job,
as this generally leads either to an injury, a poor job,
or damaged equipment.
When removing or replacing hardened pins, use a
copper or brass drift rather than a hammer.
For dismantling, overhaul, and assembly of major
and sub-components, always use the Special
Service Tools recommended. These will reduce the
work effort, labor time, and the repair cost.
Electricity
Electricity has become so familiar in day to day
usage, that its potentially dangerous properties are
often overlooked. Misuse of electrical equipment can
endanger life.
Before using any electrical equipment particularly
portable appliances - make a visual check to make
sure that the wiring is not worn or frayed and that the
plugs and sockets are intact. Make sure you know
where the nearest isolating switch for your
equipment is located.

604.64.971.00 -- 05 -- 2003
GENERAL CONSIDERATIONS
Solvents
Use cleaning fluids and solvents that are known to be
safe. Certain types of fluids can cause damage to
components such as seals and can cause skin
irritation. Solvents should be checked that they are
suitable not only for the cleaning of components and
individual parts, but also that they do not affect the
personal safety of the user.
Housekeeping
Many injuries result from tripping over or slipping on
objects or material left lying around by a careless
worker. Prevent these accidents from occurring. If
you notice a hazard, remove the hazard.
A clean, hazard-free place of work improves the
surroundings and daily environment for everybody.
Fire
Fire has no respect for persons or property. The
destruction that a fire can cause is not always fully
realized. Everyone must be constantly on guard.
Extinguish matches, cigars, and cigarettes before
throwing them away.
Work cleanly, disposing of waste material into proper
containers.
Locate the fire extinguishers and find out how to
operate them.
Do not panic - warn those near and raise the alarm.
Do not allow or use an open flame near the combine
fuel tank, battery, or component parts.
First Aid
In the type of work that mechanics are engaged in,
dirt, grease, and fine dusts settle upon the skin and
clothing. If a cut, abrasion or burn is disregarded it
may become infected within a short time. Seek
medical aid immediately.
Cleanliness
Cleanliness of the combine hydraulic system is
essential for optimum performance. When carrying
out service and repairs, plug all hose ends and
component connections to prevent dirt entry.
Clean the exterior of all components before carrying
out any form of repair. Dirt and abrasive dust
can reduce the efficiency and working life of
a component and lead to costly replacement. Use
of a high-pressure washer or steam cleaner is
recommended.
OPERATIONAL CONSIDERATIONS
Stop the engine, if at all possible, before performing
any service.
Place a warning sign on the combine which, due to
service or overhaul, would be dangerous to start.
Disconnect the battery leads if leaving such a unit
unattended.
Do not attempt to start the engine while standing
beside the combine or attempt to bypass the safety
start switch.
Avoid prolonged running of the engine in a closed
building or in an area with inadequate ventilation as
exhaust fumes are highly toxic.
Always turn the radiator cap to the first stop to allow
pressure in the system to dissipate when the coolant
is hot.
Never work beneath a combine which is on soft
ground. Always take the unit to an area which has a
hard working surface, preferably concrete.
If it is found necessary to raise the combine for ease
of servicing or repair, make sure that safe and stable
supports are installed beneath axle housings,
casings, etc., before starting work.
Use ladders or working platforms when servicing
those areas of a combine that are not within easy
reach.
WARNING
Do not use your hand to check for leaks. Use a
piece of cardboard or paper to search for leaks.
Stop the engine and relieve pressure before
connecting or disconnecting lines.
Tighten all connections before starting the
engine or pressurizing lines.
If any fluid is injected into the skin, obtain medical
attention immediately or gangrene may result.
WARNING
Escaping hydraulic/diesel fluid under pressure
can penetrate the skin causing serious injury.
Before loosening any hoses or tubes connecting
implements to remote control valves, etc., switch off
the engine, remove all pressure in the lines by
operating levers several times. This will remove the
danger of personal injury by oil pressure.

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Prior to pressure testing, make sure all hoses and
connectors of the combine and the test equipment
are in good condition and tightly sealed. Pressure
readings must be taken with the gauges specified.
The correct procedure should be rigidly observed to
prevent damage to the system or the equipment, and
to eliminate the possibility of personal injury.
Always lower equipment to the ground when leaving
the combine.
Beware of overhead power, electric or telephone
cables when travelling.
Do not park or attempt to service a combine on an
incline. If unavoidable, take extra care and block all
wheels.
Observe recommended precautions as indicated in
this Repair Manual when dismantling the air
conditioning system as escaping refrigerant can
cause frostbite.
Prior to removing wheels and tires from the combine,
check to determine whether additional ballast (liquid
or weights) has been added. Seek assistance and
use suitable equipment to support the weight of the
wheel assembly.
When inflating tires, beware of over inflation -
constantly check the pressure. Over inflation can
cause tires to burst and result in personal injury.
HEALTH AND SAFETY PRECAUTIONS
Many of the procedures associated with vehicle
maintenance and repair involve physical hazards or
other risks to health. This section lists, alphabetically,
some of these hazardous operations, materials and
equipment associated with them. The precautions
necessary to avoid these hazards are identified.
The list is not inclusive; all operations, procedures,
and handling of materials should be carried out with
health and safety in mind.
ACIDS AND ALKALIS (SEE BATTERY ACIDS,
I.E., CAUSTIC SODA, SULPHURIC ACID)
Used in batteries and cleaning materials.
Irritating and corrosive to the skin, eyes, nose and
throat. Causes burns.
Avoid splashes to the skin, eyes, and clothing. Wear
suitable protective gloves and goggles. Can destroy
ordinary protective clothing. Do not breathe mists.
Ensure access to water and soap is readily available
for splashing accidents.
ADHESIVES AND SEALERS (SEE FIRE)
CAUTION
Highly flammable, combustible.
Generally should be stored in “NO SMOKING” areas;
cleanliness and tidiness while in use should be
observed, i. e., from applications where possible,
disposable paper should be dispensed to cover
benches. Containers, including secondary contain-
ers, should be labelled.
Solvent-Based Adhesives/Sealers (See Solvents)
Follow manufacturer’s Instructions
Water-Based Adhesives/Sealers
Those based on polymer emulsions and rubber
lattices may contain small amounts of volatile toxic
and harmful chemicals.
Skin and eye contact should be avoided, and
adequate ventilation provided during use.
Follow manufacturer’s Instructions
Resin-Based Adhesive/Sealers (i.e., Epoxide and
Formaldehyde Resin Based)
Mixing should only be carried out in well-ventilated
areas as harmful or toxic volatile chemicals may be
released.
Skin contact with uncured resins and hardeners can
result in irritation, dermatitis, and absorption of toxic,
or harmful chemicals through the skin. Splashes can
damage the eyes.
Provide adequate ventilation; avoid skin and eye
contact. Follow manufacturer’s instructions.

SECTION 10 -- ENGINE -- CHAPTER 1 1
604.64.971.00 -- 05 -- 2003
SECTION 10 -- ENGINE
Chapter 1 -- 7.5L Engine
CONTENTS
Section Description Page
10 000 Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening Torques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 001 Engine Overhaul - Introduction 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Pump Timing Check 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overhaul 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 101 Cylinder Head, Valves and Related Parts 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 106 Engine Front Cover and Timing Gears 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 102 Oil Pan 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 103 Flywheel 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 102 Rear Cover Plate 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 102 Oil Pump 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 102 Oil Pressure Relief Valve 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 106 Camshaft 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Bearings 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 105 Pistons 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod Bush Replacement 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 105 Cylinder Block Overhaul 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Bore 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleeving - Boring and Honing 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Piston Assembly Into Block 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 103 Crankshaft 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 003 Front Crankshaft Cassette Oil Seal Replacement 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 001 Engine Compression Test 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

604.64.971.00 -- 05 -- 2003
DESCRIPTION AND OPERATION
2
The 7.5 Litre engine is a 6-cylinder turbocharged and
aftercooled, having a bore of 111.8 mm (4.4″) and a
stroke of 127 mm (5.0″) which generates a
displacement of 7.5L (456 in3).
The engine uses a mechanical or electronically
controlled in line injection pump depending on model
and has been designed to meet current emission
regulations and must only be serviced by an
authorized service agent. For a detailed description
and operation of the fuel system, reference must be
made to the “Fuel System” chapter in this Section of
the manual.
All engines feature cross flow cylinder heads, with the
inlet and exhaust manifolds on opposite sides of the
cylinder head. The fuel and air combustion process,
takes place in the specially designed bowl in the
crown of the pistons.
Cylinder Block Assembly
The cylinder block is an alloy cast iron with deep
cylinder skirts, and water jackets for cooling the
cylinders. The cylinder bores are machined integral
with the cylinder block, during the manufacturing
process.
Cylinders are in line and vertical and numbered 1 to
6 from the front to the rear of the engine. They can be
bored oversize for the fitment of sleeves, which are
available in service.
The oil pan is the reservoir for the engine oil
lubrication system and a cast iron front cover on the
front of the engine covers the timing gear assembly.

16 SECTION 10 -- ENGINE -- CHAPTER 1
604.64.971.00 -- 05 -- 2003
Cylinder Head Assembly
The cylinder head incorporates an inlet and exhaust
valve per cylinder with the valve rocker arm shaft
assembly bolted to the cylinder block through the
cylinder head. Cylinder head retaining bolts are
evenly spaced with a six point pattern around each
cylinder, this ensures an even clamping load across
the cylinder head area.
The intake and exhaust manifolds are bolted to the
head, the intake manifold is mounted on the right
hand side of the engine, with the diesel injectors
mounted outside the rocker cover. The exhaust
manifold is mounted on the left hand side of the
engine. Water outlet connections and thermostats
being attached to the front of the cylinder block.
Valve guides are integral in the cylinder head, and
valves with oversize stems are available in service.
Special replaceable sintered iron valve seats are
pressed into each valve port during manufacture and
oversize valve seats also available in service.
All valves are fitted with positive valve rotators and
valve stem oil seals. Valve clearance is maintained by
adjustment of the self locking adjusting screw,
mounted in each of the rocker arms.
3
Camshaft Assembly
The camshaft runs in 5 replaceable bearings. The
camshaft drive gear is in mesh with and driven by the
camshaft idler gear which is driven by the crankshaft
timing gear.
Camshaft end thrust is controlled by a thrust plate
bolted to the block, and located between the
camshaft gear and the front camshaft journal.
A helical gear is mounted on the rear of the camshaft,
and drives the engine oil lubrication pump mounted
forward of the flywheel.
396--E--16 TI
4
Crankshaft Assembly
The crankshaft is supported in the cylinder block by
7 main bearings.
The crankshaft is manufactured from steel with
machined finished crank webs
End thrust is controlled by a thrust bearing
incorporated in the center main bearing of the
crankshaft.
An external damper is fitted to the crankshaft pulley
to ensure smooth running operation. Front and rear
crankshaft oil sealing is effected by cassette type
seals that are designed for long and durable service
life. 5

604.64.971.00 -- 05 -- 2003
Connecting Rods
Connecting rods ‘‘Teepee” (wedge) shaped at the
small end have been designed to reduce the
reciprocating weight at the piston end. The
connecting rods are of a heavy beam construction
and are assembled as a matched set to each engine.
They are retained in position by the connecting rod
big end cap and secured by two bolts per rod. The
small end of the connecting rod is fitted with a
replaceable bronze bushing, through which the free
floating piston pin is fitted. The steel pin being held in
place within the piston by two snap rings.
6
Pistons
Pistons are constructed of an aluminium silicon alloy
with an iron insert for the top ring. The combustion
chamber being recessed into the piston crowns.
Each piston has two compression rings and one oil
control ring, to reduce friction and increase positive
sealing. All rings are located above the piston pin.
A Engines with Electronically Controlled
Injection Pump
B Engines with Mechanically Controlled
Injection Pump
7
Manifolds
The cross flow design aluminium intake, and cast iron
exhaust manifolds, are on opposite sides of the
cylinder head. This is designed to maintain balanced
heat distribution within the cylinder head. The
configuration of the manifolds also ensures minimum
heat transfer to the intake manifold.
A grid heater is fitted to the intake manifold to assist
in cold starting of the engine when coolant water
temperature is below 30°C.
8

604.64.971.00 -- 05 -- 2003
Timing Gears
The crankshaft timing gear is heated and press fitted
on to the front of the crankshaft, to a high degree of
accuracy during manufacturing. This enables precise
timing being maintained during the life of the engine.
The crankshaft gear, 2, drives the idler gear, 3, which
is attached to the front of the cylinder block. The idler
gear then drives the camshaft gear, 1, and the
injection pump gear, 4.
The camshaft gear is bolted to the front of the
camshaft, and is keyed to maintain position of the
gear on the camshaft.
P396--E--36
.
...
.
23
4 1
9
Lubrication System
10
Engine Lubrication System
Lubrication of the engine, Figure 10, is maintained by
a rotor type oil pump mounted in the rear of the engine
block, forward of the flywheel on the left hand side of
the engine.
TA6010058
11

604.64.971.00 -- 05 -- 2003
The oil pump is driven from the rear of the camshaft
and draws oil from the engine oil pan through a tube
and screen assembly.
12
A spring loaded relief valve is integral with the dummy
oil filter head mounted on the left hand side of the
engine block and prevents over pressurisation of the
system.
396--E--18 TI
3
13
The spin on type oil filter is mounted at the rear of the
engine.
14

604.64.971.00 -- 05 -- 2003
Oil flows from the filter to the main oil gallery, which
runs the length of the cylinder block and also
intersects the camshaft follower chamber.
The main gallery supplies oil to the crankshaft main
bearings, connecting rods and both big and small
ends. The underside of the pistons and pins, are
lubricated by oil pressure jets mounted adjacent to
each main journal housing.
The camshaft drive gear bushing is pressure
lubricated through a drilled passage from the front
main bearing. The gear has small oil passages
machined on both sides allowing excess oil to
escape. 396--E--26 TI
15
An intermittent flow of oil is directed to the valve
rocker arm shaft assembly via a drilled passage in the
cylinder block. This is located vertically above No.1
camshaft bearing, 1, and aligns to a hole in the
cylinder head. The rotation of the camshaft allows a
controlled intermediate flow of lubrication.
396--E--16 TI
1
16
Timing gears are lubricated by splashed oil from the
cam follower chamber, and the pressure lubricated
camshaft drive gear bushing.
P396--E--36
17

604.64.971.00 -- 05 -- 2003
The turbocharger is supplied with oil from the oil filter
support housing, 1, mounted on the left hand side of
the engine.
18
The fuel injection pump is pressure lubricated from a
port, 1, on the right hand side of the engine block.
The fuel pump is either electronically controlled using
an electronic control unit, Figure 19 or mechanically
controlled depending on model build, Figure 20.
19
20

604.64.971.00 -- 05 -- 2003
ENGINE OVERHAUL -- INTRODUCTION
In the following procedures and illustrations the
engine is shown removed from the vehicle however
there are certain operations that can be performed
with the engine installed.
Where it is necessary to remove the engine use a
suitable hoist or overhead gantry and standard
engineering procedures. Removal of the engine is
described in Section 10, Chapter 3 of this manual.
Dismantle the engine following conventional
techniques and by referring to the appropriate
overhaul sections of this chapter. Always refer to the
specification section as necessary.
NOTE: Where it is necessary to remove additional
items to gain access to the components on the engine
Refer to Chapter 3 “Remove and Replace, 7.5L
Engine”.
NOTE: All gaskets, seals, and O rings must be
replaced during re-assembly. Where new sealant is
to be applied refer to ‘‘Engine Specifications”.
For concerns relating to the fuel system refer to the
“Fuel System” chapter in this manual. On engines
fitted with the electronically controlled fuel injection
pump refer to the “Engine Fault Codes” chapter in the
electrical section of the manual.
Operations or repairs that can be performed
with the engine still in the vehicle.
1. Front timing cover, Pump drive gear and idler
gear. Removal of engine is required in order to
remove and replace the camshaft timing gear.
2. Front pulley and damper assembly.
3. Cylinder head and associated inlet and exhaust
components.
4. Fuel injection pump removal and timing.
5. Water pump, thermostat, and associated
components .
6. Oil pump relief valve.
7. Turbocharger.

604.64.971.00 -- 05 -- 2003
INJECTION PUMP TIMING CHECK
If a fuel related concern is identified check the
injection pump timing before proceeding with any
other disassembly.
NOTE: Where it is necessary to remove additional
items to gain access to the components on the engine
Refer to Chapter 3 “Engine Removal and
Replacement”.
1. Remove engine drive belts.
21
2. Remove injection pump timing cover.
22
3. Using 29 mm (1-1/8″) socket rotate crankshaft to
top dead center (TDC) with number 1 cylinder
firing.
0
23

604.64.971.00 -- 05 -- 2003
4. When engine is at TDC the threaded hole in the
injection pump drive flange aligns with the pump
timing plate.
24
5. To ensure the crankshaft is accurately positioned
at TDC remove the crankshaft timing plug, 1,
from the side of the engine block.
IMPORTANT: DO NOT disturb the timing pin bush,
2. This has been accurately set during original
manufacture. If the bush is moved then pump timing
CAN NOT be accurately set.
25
6. insert the crankshaft timing pin 297672 into the
side of the block.
26

604.64.971.00 -- 05 -- 2003
7. If necessary gently turn the crankshaft to engage
the rounded end of the timing pin in the slot of the
crankshaft. This is not visible and must be
performed by ‘feel’.
27
8. When the timing pin is located in the slot of the
crankshaft the pin is fully seated.
Do Not attempt to rotate the crankshaft when
timing pin is fully inserted as damage will occur.
28
9. Check that the injection pump go/no-go timing pin
Tool No 295005 (NA-FNH00536-2) will screw into
the pump hub.
IMPORTANT: The engine must never be rotated
while the timing pin is installed.
10. If the pin engages in the pump timing plate (inset,
Figure 30) when the crankshaft is at TDC the
pump timing is correct.
29

604.64.971.00 -- 05 -- 2003
11. If pump timing is incorrect and timing pin can not
be screwed into pump, remove pump timing gear,
install rigid timing pin 295005 (NA-FNH00536-1)
into pump and refit timing gear.
30
NOTE: This injection pump timing check assumes
that the crankshaft and camshaft timing gears were
correctly positioned during engine assembly. To
check the position of these timing gears it is
necessary to remove the engine front cover.

604.64.971.00 -- 05 -- 2003
OVERHAUL
Op. 10 101
CYLINDER HEAD, VALVES AND RELATED
PARTS
Cylinder Head Removal
NOTE: The cylinder head can be removed with the
engine installed in the combine.
1. Drain the engine coolant by placing a suitable
container,1, below the coolant drain hose, 2.
10013105
1
2
31
2. Drain the coolant from the engine block using
drain tap, 1, on left hand side of the radiator, 2.
10013106
1
2
32
3. Remove all necessary hardware and
components in order to gain access to the
cylinder head. Refer to Chapter 3 “Remove and
Replace, 7.5L Engine” for further details.
33

604.64.971.00 -- 05 -- 2003
4. Remove the fan belt.
34
5. Clean the area surrounding the fuel injectors.
Disconnect and remove injector lines, 1, and leak
off lines, 2, from the fuel injectors and injection
pump. Cap all exposed openings.
2
1
35
6. Remove injectors from the cylinder head.
36

604.64.971.00 -- 05 -- 2003
7. Remove the turbocharger assembly, ensuring all
openings are capped to prevent dirt ingress.
37
8. Remove the thermostat housing, 1, and water
pump housing, 2.
38
9. Remove the rocker cover and gasket.
39

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604.64.971.00 -- 05 -- 2003
10. Loosen the rocker shaft retaining bolts (which
also serve as head bolts) evenly and alternately
and remove the rocker shaft assembly.
40
NOTE: Leave bolts in the rocker shaft supports
during removal, as they retain the support on the
shaft.
11. Remove pushrods in turn and place in a
numbered rack to maintain the same position for
reassembly.
41
12. Remove remaining cylinder head bolts by
working progressively from each end of the
cylinder head towards the center.
13. Carefully lift the cylinder head assembly away
from the engine block.
42

604.64.971.00 -- 05 -- 2003
Cylinder Head Disassembly
1. Using a valve spring compressor, Tool No.
291050, 1, remove the retainer locks, 2, and
place in a numbered rack.
2. Clean the cylinder head, and remove carbon
deposits from around the valve heads.
TA6010011
1
2
43
44
Inlet and Exhaust Valves
1. Keepers
2. Spring Retainer
3. Seal
4. Spring
5. Inlet Valve
6. Exhaust Valve
7. Spring
8. Seal
9. Spring Rotator
10. Spring Rotator
11. Keepers

604.64.971.00 -- 05 -- 2003
Cylinder Head - Inspection and Repair
1. Replace cylinder head core plugs if discoloured
(rusty), or leaking. Before fitting new plugs
remove all old sealer from the cylinder head.
Apply sealant G to the new plug mating faces,
and drive the new plugs into location, (refer to
‘‘Specifications”).
The core plugs fitted to the cylinder head are:
• 6 off, in the top, and 1 off, in the rear of the cyl-
inder head.
• 5 off, in the intake face.
2. Scrape all gasket surfaces clean, wash cylinder
head in a suitable solvent and clean valve guide
bores.
NOTE: Ensure injector washers have been removed
prior to cleaning.
TA6010008
45
3. Inspect cylinder head for nicks and burrs on
mating face. Remove using a suitable abrasive
and ensure faces are clean after repair.
4. Using a straight edge and feeler gauges, check
that the flatness of the cylinder head in all
directions does not exceed, 0.03 mm (0.001 in.)
in any 25.4 mm (1 in.), or 0.127 mm (0.005 in.),
overall limit.
5. If the cylinder head has been resurfaced,
determine that all head bolt faces will seat by
placing the cylinder head less gasket, on the
cylinder block and installing bolts hand tight.
TA6010012
2 3 4 5 6 6 7 8
46
6. Ensure rocker shaft supports are fitted with long
bolts. Using a feeler gauge, check clearance
between underside of bolt heads and cylinder
head or rocker shaft support.
7. If a 0.25 mm (0.010 in.) feeler gauge can be
inserted under the bolt head the bolt has bottomed.
Therefore the cylinder block thread must be
increased using a 9/16″-13 UNC-2A thread tap.
Identify each head bolt to ensure they are
re-installed in the bolt holes they were checked in.
47

604.64.971.00 -- 05 -- 2003
Valve Inserts
Insert Oversize
Counter Bore in Cylinder Head
Insert Oversize
Exhaust Valve Insert Intake Valve Insert
0.25 mm (0.010 in.) 44.17 - 44.20 mm (1.739 - 1.740 in.) 50.01 - 50.04 mm (1.969 - 1.970 in.)
0.58 mm (0.020 in.) 44.42 - 44.45 mm (1.749 - 1.750 in.) 50.27 - 50.29 mm (1.979 - 1.980 in.)
0.76 mm (0.030 in.) 44.68 - 44.70 mm (1.759 - 1.760 in.) 50.52 - 50.55 mm (1.989 - 1.990 in.)
NOTE: Refacing the valve seat should always be
coordinated with refacing of the valve to ensure a
compression tight fit.
1. Examine the valve seat inserts and reface if
pitted, renew if loose or damaged.
2. To install a new valve insert, the cylinder head
must be counter bored, as described in the above
chart. The new insert must be chilled in dry ice
prior to installation.
Valve Seat Specifications, Figure 48.
1. Valve seat angle
Intake 30.0°--30.30°
Exhaust 45.0°--45.30°
2. Valve seat width
Intake 1.9 - 2.4 mm (0.078 - 0.098 in.)
Exhaust 1.8 - 2.3 mm (0.072 - 0.092 in.)
3. Valve Head Face to Cylinder Head Face Depth
Intake 0.89 - 1.29 mm (0.035 - 0.051 in.)
Exhaust 1.2 - 1.6 mm (0.048 - 0.064 in.)
NOTE: Valve inserts of 0.25 mm (0.010 in.) and 0.5
mm (0.020 in.) oversize on diameter are sometimes
installed during manufacture. Cylinder Heads with
oversize inserts are stamped so10/os, so20/os, on
the exhaust manifold side in line with the valve seat
concerned.
3. Check the width of the valve seat inserts, and as
required reface by grinding to dimensions
detailed above.
TA6010013
1
2
3
48
4. Measure the concentricity of valve seats, using a
dial indicator and measure concentricity of seat to
the valve guide bore. Total Indicator Reading
should not exceed 0.051 mm (0.002 in.),
Figure 49.
49

604.64.971.00 -- 05 -- 2003
5. Use a seat cutter to correct any seat eccentricity,
or clean up of pits and grooves. Ensure after any
rework that seat width is within specified limits.
6. Rotate a new or refaced valve in the seat using
engineering blue, ensure all the blue is
transferred to the valve head protrusion, If any
blue remains below or around the seat raise or
lower the seat accordingly, Figure 50, in the
following manner.
7. Lower, the valve seats, 1, Figure 50, by removing
material from the top of seat using a, 30° grinding
wheel for exhaust valves and a 15° grinding
wheel for intake valves.
8. Raise, the valve seats, 2, Figure 50, by removing
material from the bottom of seat using a, 60°
grinding wheel for exhaust valves and a 45°
grinding wheel for intake valves.
TA6010016
50
Critical valve points, Figure 51:
1. Valve Land Edge
2. Valve Head
3. Valve Face Angle
4. Valve Face
5. Valve Stem
6. Valve Tip
Valve Guides
1. Using a telescopic gauge, and micrometer,
measure the valve guide bore clearance, and
ensure it does not exceed, 0.114 mm(0.0045 in.),
on the intake valve stem, and 0.140 mm
(0.0055 in.), on the exhaust valve stem,
Figure 52.
51
NOTE: Production cylinder heads may have one or
more machined, oversize valve guide bores, or
valves installed, 0.38 mm (0.015 in.). Such cylinder
heads have 15 or VO15OS stamped on the cylinder
head exhaust manifold side adjacent to the valve
concerned.
2. Using reamer set, 295006 (NA-FNH02136),
ream out the valve stem guide, with three reamer
and pilot combinations as follows:
When going from a standard valve stem to an
oversize, always use reamers in sequence
0.38 mm (0.015 in.) oversize reamer, and 0.076
mm (0.003 in.) oversize pilot.
TA6010018
52

604.64.971.00 -- 05 -- 2003
Valve Springs
1. Checked on a flat surface squareness, should not
exceed 1.52 mm (0.060 in.), between the square,
and spring at the top edge, Figure 53.
Length of valve springs should be checked on
both free length, and loaded length.
• Free length = 60.7 mm (2.39 in.)
• Installed length = 47 - 49.6 mm (1.86 -
1.95 in.)
• Loaded length = 48.26 mm (1.9 in.) using a
weight of 28 - 31 kg (61.96 lbs.)
• Loaded length = 35.69 mm (1.4 in.) using a
weight of 61 - 69 kg (135 - 153 lbs.)
Ensure the valve spring retainer locks are in good
condition and replace if worn or damaged. 53
Rocker Shaft Inspection and Reassembly
1. Separate rocker shaft assembly by removing the
cylinder head bolts, 3, and withdraw the supports,
2, springs, 1, rockers, 4, and spacers, 6.
2. Clean all components using approved cleaning
solution and make sure all oil passages are clear.
3. Inspect rocker arm adjusting screws, and push
rod ends of the rocker arm, including the ball end
of the screws for nicks, damage, or excessive
wear.
4. Inspect the inside diameter of the rocker arm for
damage or wear. If any of these characteristics
are not to specification replace with new parts.
6 5
TA6010010
2 3
4
1
54
5. Check the ends of the push rods for damage or
wear. If not to specification or push rods were
found not to be straight during dismantling install
new rods.
NOTE: Do not attempt to straighten bent push rods,
replace with new.
6. Check the rocker shaft for signs of wear or
damage on internal and external diameters
respectively.
7. Re-assemble the rocker shaft components onto
the shaft ensuring the shaft identification groove,
1, is positioned forwards and upwards. This
ensures oil grooves and holes face downwards. 55

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