New holland cx840 combine service repair manual

87360012 8/05© 2005 CNH AMERICA LLC
Printed In U.S.A.
CX SERIES REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 - ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 - LIVE PTO 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 21 - TRANSMISSION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 25 - FRONT MECHANICAL DRIVE 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 29 - HYDROSTATIC SYSTEM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 33 - BRAKES AND CONTROL 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 35 - HYDRAULIC SYSTEMS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 41 - STEERING AXLE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 50 - CLIMATE CONTROL 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 55 - ELECTRICAL SYSTEMS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 60 - PRODUCT FEEDING 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 66 - THRESHING 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 72 - SEPARATION 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 74 - CLEANING SYSTEMS 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 80 - GRAIN STORAGE 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 88 - ACCESSORIES 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 90 - PLATFORM AND CAB 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following pages are the collation of the contents pages from each section and
chapter of the CX Series Repair manual. Complete Repair part # 86630597.
The sections used through out all New Holland product Repair manuals may not be
used for each product. Each Repair manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair manual and
which sections are in each book.
The sections listed above are the sections utilized for the CX Series Combines.

SECTION 00 -- GENERAL INFORMATION
00-1
CONTENTS
Section Description Page
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General instructions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shimming 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating shaft seals 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O--ring seals 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing compounds 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cotter pins 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety regulations 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accident prevention 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety rules 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General guidelines 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-up 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic systems 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels and Tyres 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Re-fitting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explanation of machine serial numbers 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of measure -- Conversion chart 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum hardware tightening torques 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drives 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main output shaft 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading output shaft 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00-2
INTRODUCTION
This manual is subdivided in sections marked by two-digit numbers, with independent page numbering within
each section. For a quick reference, these sections have the same identification number and the same descrip-
tion of the relevant Flat Time Rate Manual.
The dealt matters and the information can be easily detected by index on the previous pages.
At the bottom of each page there is the manual print number and the relevant publication/up-dating date.
The pages of further up-datings shall have the same print number, followed by a two-digit number (for example:
1st Up-dating 604.62.501.01; 2nd Up-dating 604.62.501.02; etc.) and the relevant publication date. These pages
shall be completed by the new print of the index, duly revised.
The information of this manual are up-dated at the date of the publication. As NEW HOLLAND continuously im-
proves its product range, some information could be not up-dated due to modifications of technical or commercial
type, as well as for suiting the law regulations of the different countries.
In case of disagreement, refer to NEW HOLLAND Sales and Service networks.
IMPORTANT INFORMATION
All repair and maintenance works listed in this manual must be carried out only by staff belonging to the NEW
HOLLAND Service network, strictly complying with the instructions given and using, whenever required, the
special tools.
Anyone who carries out the above operations without complying with the prescriptions shall be responsible for
the subsequent damages.
The manufacturer and all the organizations of its distribution chain, including -- without limitation -- national, re-
gional or local dealers, reject any responsibility for damages due to the anomalous behaviour of parts and/or
components not approved by the manufacturer himself, including those used for the servicing or repair of the
product manufactures or marketed by the Manufacturer.
In any case, no warranty is given or attributed on the product manufactures of marketed by the Manufacturer
in case of damages due to an anomalous behaviour of parts and/or components not approved by the Manufac-
turer.
No reproduction, though partial of text and illustrations allowed

00-3
GENERAL INSTRUCTIONS
SHIMMING
For each adjustment operation, select adjusting
shims and measure individually using a micrometer,
then add up the recorder values. Do not rely on
measuring the entire shimming set, which may be in-
correct, or the rated value indicated for each on shim.
ROTATING SHAFT SEALS
For correct rotating shaft seal installation, proceed as
follows:
-- before assembly, allow the seal to soak in the oil
it will be sealing for at least thirty minutes
-- thoroughly clean the shaft and check that the
working surface on the shaft is not damaged
-- position the sealing lip facing the fluid; with
hydrodynamic lips, take into consideration the
shaft rotation direction and position the grooves
so that they will deviate the fluid towards the inner
side of the seal
-- coat the sealing lip with a thin layer of lubricant
(use oil rather than grease) and fill the gap
between the sealing lip and the dust lip on double
lip seals with grease
-- insert the seal in its seat and press down using a
flat punch, do not tap the seal with a hammer or
mallet
-- whilst inserting the seal, check that it is
perpendicular to the seat; once settled, make
sure that it makes contact with the thrust element,
if required
-- to prevent damaging the seal lip on the shaft,
position a protective guard during installation
operations
O--RING SEALS
Lubricate the O--RING seals before inserting them in
the seats, this will prevent them from overturning and
twisting, which would jeopardise sealing efficiency.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the
mating surfaces marked with an X: RTV SILMATE,
RHODORSIL CAF 1 or LOCTITE PLASTIC
GASKET.
Before applying the sealing compound, prepare the
surfaces as follows:
-- remove any incrustations using a metal brush;
-- thoroughly de--grease the surfaces using one of
the following cleaning agents: trichlorethylene,
petrol or a water and soda solution.
COTTER PINS
When fitting split cotter pins, ensure that the pin notch
is positioned in the direction of the force required to
stress the pin.
Spiral cotter pins do not require special positioning.

00-4
PROTECTING THE ELECTRONIC/
ELECTRICAL SYSTEMS DURING
CHARGING OR WELDING
To avoid damage to the electronic/electrical systems,
always observe the following:
1. Never make or break any of the charging circuit
connections, including the battery connections,
when the engine is running.
2. Never short any of the charging components to
ground.
3. Always disconnect the ground cable from the
battery before arc welding on the combine or on
any header attached to the combine.
• Position the welder ground clamp as close to
the welding area as possible.
• If welding in close proximity to a computer
module, then the module should be removed
from the combine.
• Never allow welding cables to lay on, near or
across any electrical wiring or electronic
component while welding is in progress.
IMPORTANT: If welding must be performed on the
unit, either the combine or the header (if it is
attached), the battery ground cable must be
disconnected from the combine battery. The
electronic monitoring system and charging system
will be damaged if this is not done.
Remove the battery ground cable.
Reconnect the cable when welding is
completed.
4. Always disconnect the negative cable from the
battery when charging the battery in the combine
with a battery charger.
WARNING
Batteries contain sulfuric acid. In case of contact
with skin, flush the affected area with water for
five minutes. Seek medical attention
immediately. Avoid contact with the skin, eyes or
clothing. Wear eye protection when working near
batteries.

SECTION 10 -- ENGINE -- CHAPTER 1
10-1
SECTION 10 -- ENGINE
Chapter 1 -- 7.5L New Holland Engine
CONTENTS
Section Description Page
10 000 Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening Torques 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greases and Sealants 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Finding 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 001 Engine Overhaul--Introduction 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Pump Timing Check 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 100 Engine Disassembly and Overhaul:--
10 101 Cylinder Head, Valves and Related parts 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 106 Front Cover and Timing Gears 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 102 Oil Pan 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 103 Flywheel 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 102 Rear cover plate 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 102 Oil pump 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 102 Oil Pressure Relief Valve 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 106 Camshaft, tappets and camshaft bearings 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 105 Pistons and Cylinder Block 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 103 Crankshaft 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 001 Engine compression test 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-17
DESCRIPTION AND OPERATION
2
The New Holland 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
authorised 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.

10-18
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 centre 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

10-19
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
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

10-20
LUBRICATION SYSTEM
10
Engine Lubrication System
Lubrication of the engine, Fig. 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
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

10-21
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
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

10-22
Timing gears are lubricated by splashed oil from the
cam follower chamber, and the pressure lubricated
camshaft drive gear bushing.
P396--E--36
17
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
19
or
Mechanically controlled depending on model build
20

10-23
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 Chapter 3 of Section 10 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 NH
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.

10-24
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
1. Remove injection pump timing cover.
22
2. Using 29mm socket (1--1/8 inch) socket rotate
crankshaft to top dead centre (TDC) with number
1 cylinder firing.
0
23
3. When engine is at TDC the threaded hole in the
injection pump drive flange aligns with the pump
timing plate.
24

10-25
4. 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
5. insert the crankshaft timing pin 297672 into the
side of the block.
26
6. 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
7. 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

10-26
8. 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.
9. If the pin engages in the pump timing plate (inset,
Figure 30) when the crankshaft is at TDC the
pump timing is correct.
29
10. 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.

10-27
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 NH Engine” for further details.
33
4. Remove the fan belt.
34

10-28
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
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

10-29
9. Remove the rocker cover and gasket.
39
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 centre.
13. Carefully lift the cylinder head assembly away
from the engine block.
42

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10-30
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

10-31
Inspection and Repair, Cylinder Head
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, see ‘‘SPECIFICATIONS”, to the
new plug mating faces, and drive the new plugs
into location.
The core plugs fitted to the Cylinder Head are:--
6 off, In the top, and 1 off, in the rearof the cylinder
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,
0.03mm (0.001 in) in any (25.4mm (1 in), or
0.127mm (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 0.25mm (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 reinstalled in the bolt holes they werechecked
in.
47

10-32
Valve Inserts
Insert Oversize
Counter Bore in Cylinder Head
Insert Oversize
Exhaust valve insert Intake valve insert
0.25mm (0.010 in) 44.17--44.20mm (1.739--1.740 in) 50.01--50.04mm (1.969--1.970 in)
0.58mm (0.020 in) 44.42--44.45mm (1.749--1.750 in) 50.27--50.29mm (1.979--1.980 in)
0.76mm (0.030 in) 44.68--44.70mm (1.759--1.760 in) 50.52--50.55mm (1.989--1.990 in)
NOTE: Refacing the valve seat should always be co--
ordinated with refacing of the valve to ensure a com-
pression 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, Fig. 48.
1. Valve seat angle
Intake 30.0°--30.30°
Exhaust 45.0°--45.30°
2. Valve seat width
Intake 1.9--2.4mm (0.078--0.098 in)
Exhaust 1.8--2.3mm (0.072--0.092 in)
3. Valve Head Face to Cylinder Head Face Depth
Intake 0.89--1.29mm (0.035--0.051 in)
Exhaust 1.2--1.6mm (0.048--0.064 in)
NOTE: Valve inserts of 0.010 in (0.25mm) and
0.020 in (0.5mm) 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
0.051mm (0.002 in), Fig. 49.
49

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