New Holland CR960, CR980 Service Manual

Print No. 604.64.971.00 NEW HOLLAND REPAIR MANUAL CR920 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

CONTENTS 1 604.64.971.00 - 07 - 2003 CONTENTS 00 - GENERAL INFORMATION 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 CONTENTS 604.64.971.00 - 07 - 2003 10 - ENGINE Chapter 1 -- 7.5L New Holland Engine Specifications 2 ................................................................ Tightening Torques 8 ............................................................ Special Tools 9 ................................................................. Troubleshooting 11 ............................................................... Description and Operation 15 ..................................................... Engine Overhaul - Introduction 22 ................................................. Injection Pump Timing Check 23 .................................................. Overhaul 27 .................................................................... Cylinder Head, Valves and Related Parts 27 ........................................ Engine Front Cover and Timing Gears 40 .......................................... Oil Pan 45 ..................................................................... Flywheel 46 .................................................................... Rear Cover Plate 48 ............................................................ Oil Pump 50 .................................................................... Oil Pressure Relief Valve 52 ...................................................... Camshaft 53 ................................................................... Camshaft Bearings 54 ........................................................... Pistons 56 ..................................................................... Connecting Rod Bush Replacement 58 ............................................ Cylinder Block Overhaul 60 ...................................................... Cylinder Bore 61 ................................................................ Sleeving - Boring and Honing 62 .................................................. Installing Piston Assembly Into Block 65 ........................................... Crankshaft 66 .................................................................. Front Crankshaft Cassette Oil Seal Replacement 71 ................................. Engine Compression Test 77 ..................................................... Chapter 2 -- Cooling system Description and Operation 2 ...................................................... Cooling System 2 ............................................................... Troubleshooting 4 ............................................................... Specifications 5 ................................................................ Disassembly and Repair 6 ....................................................... Chapter 3 -- Remove and replace, 7.5L NH Engine Engine 2 ....................................................................... Engine Removal 2 .............................................................. Engine Installation 17 ............................................................

CONTENTS 3 604.64.971.00 - 07 - 2003 Chapter 4 -- Fuel system, 7.5L NH Engine Specifications 2 ................................................................ Torque Chart 2 ................................................................. Special Tools 3 ................................................................. Description and Operation 4 ...................................................... Bosch P7100 Mechanically Controlled Fuel Injection System 6 ........................ Bosch P7100 Electronically Controlled Fuel Injection System 12 ...................... Fuel Injector Assemblies 17 ...................................................... Injection Pump Timing Check 19 .... .................................................. Adjustments and Diagnosis 23 .................................................... Low Idle and Anti-Surge 23 ....................................................... Fuel Shutoff Diagnosis 23 ........................................................ Maintenance 25 ................................................................ Fuel Prefilter/Water Separator 25 ................................................. Fuel Filter/Water Separator 26 .................................................... Supply Pump Sedimenter 26 ..................................................... Bleeding the Fuel System 27 ..................................................... Component Overhaul 28 ......................................................... Injection Pump 28 ............................................................... Fuel Lift Pump 33 ............................................................... Fuel Shutoff Solenoid 34 ......................................................... Low Pressure Fuel Injection Lines 35 .............................................. High Pressure Fuel Injection Lines 36 ............................................. Fuel Injectors 38 ................................................................ Injector Testing 39 .............................................................. Injector Overhaul 41 ............................................................. Chapter 5 -- 7.8L, 10.3L Description of operation Walk Around 2 ................................................................. The 7.8L, 10.3L Engines 7 ....................................................... Engine Block and Cylinder Liners 9 ................................................ Crankshaft 9 ................................................................... Crankshaft Sealing Rings 10 ..................................................... Connecting Rods 10 ............................................................. Pistons 10 ..................................................................... Camshaft 11 .................................................................... Timing System 11 ................................................................ Flywheel 12 .................................................................... Auxiliary Drive Belt 13 ........................................................... Lubrication 14 .................................................................. Oil Filter 15 .................................................................... Oil Sump 16 .................................................................... Cooling 16 ..................................................................... Electronically Controlled Injection System 17 ....................................... Pump Injector 18 ............................................................... Chapter 6 -- Remove and replace, Engine Engine 2 .......................................................................

4 CONTENTS 604.64.971.00 - 07 - 2003 Chapter 7 -- Engine General Specifications 3 ......................................................... Fuel System Data 7 ............................................................. Main Data 8 .................................................................... Torque Settings 17 .............................................................. Plan of Tightening Sequence of Screws Securing Sub-Crankcase 27 .................. Tools 30 ....................................................................... Lubrication Diagram 33 .......................................................... Fuel Supply System Diagram 34 .................................................. Mechanical Troubleshooting 36 ................................................... Engine - Disassembly and Assembly 39 ........................................... Assembling Crankshaft With Main Bearing Caps, Thrust Bearings and Rings, Crankshaft End Float 50 ......................................................... Assembling Pistons With Piston Rings, Pins, Connecting Rods, Connecting Rod Caps and Bearings - Checking Protrusion Over the Top Face of the Crankcase 53 ............ Fitting and Tightening the Cylinder Head 55 ........................................ Fitting Oil Pump, Timing System Intermediate Gears and Gear Box 56 ................. Engine Flywheel Assembly 58 .................................................... Fitting Camshaft 59 ............................................................. Fitting Injectors - Pump 60 ....................................................... Fitting Rocker Arm Shaft 60 ...................................................... Completing the Engine 64 ........................................................ Assembly Diagram For Fan Drive Belt - Water Pump - Alternator For F2B Engine 67 ..... Assembly Diagram For Fan Drive Belt - Water Pump - Alternator For F3A Engine 68 ..... Checks, Measurements and Repairs on the Crankcase, Cylinder Liners 69 ............. Checks, Measurements and Repairs on the Crankshaft, Bearings 72 .................. Selecting Main and Big End Bearing Shells 76 ...................................... Preliminary Appraisal of Data to Make the Selection 77 .............................. Checks, Measurements and Repairs on the Pistons 86 .............................. Checks, Measurements and Repairs on the Connecting Rods 89 ...................... Piston Connecting Rod Assembly 92 .............................................. Checks, Measurements and Repairs on the Cylinder Head 95 ........................ Valve Seats On The Head 98 ..................................................... Checks, Measurements and Repairs on the Tappets And Camshaft 99 ................. Checks, Measurements and Repairs on the Valve Springs, Rocker Arm Shaft and Rocker Arms 103 ........................................................... Rocker Arms 106 ............................................................... Checks, Measurements and Repairs on the Lubrication System 106 ................... Cooling 111 ..................................................................... Checks, Measurements and Repairs on the Cooling Circuit 111 ........................ Fuel Supply 113 ................................................................ Valve Guides 115 ............................................................... Injector Case 116 ............................................................... Replacing the Crankshaft Front Cover Seal 119 ..................................... Adjusting Clearance Valve of Intake Exhaust Rocker Arms and Pre-Load of Pump Injector Rocker Arms 120 .................................................. Pump Injector - Removal and Refitting 121 ......................................... Bleeding the Fuel Supply System 125 ............................................. Water Pump 126 ................................................................ Thermostat 126 .................................................................

CONTENTS 5 604.64.971.00 - 07 - 2003 14 - LIVE PTO Chapter 1 -- Engine gearbox, Clutch pack Removal/Installation Special Torque 2 ................................................................ Special Tool 2 .................................................................. General 3 ...................................................................... Labor Guide 3 .................................................................. Clutch Pack Removal/Installation with the Gearbox Installed 4 ........................ Chapter 2 -- Engine gearbox, Clutch pack rebuild Main Clutch Disassembly 2 ...................................................... Main Clutch Assembly 6 ......................................................... Unload Clutch Disassembly 12 ................................................... Unload Clutch Assembly 15 ...................................................... Chapter 3 -- Engine gearbox, Removal/Installation Gearbox 2 ..................................................................... Flexplate 21 .................................................................... Chapter 4 -- Engine gearbox, Rebuild Gearbox Disassembly 2 ......................................................... Inspection 8 .................................................................... Bearing and Race Removal/Installation 10 ......................................... Clutch Cylinder Bushing Removal 10 .............................................. Clutch Cylinder Bushing Installation 11 .............................................. Gearbox Assembly 13 ........................................................... 21 - TRANSMISSION Chapter 1 -- Transmission Specifications 2 ................................................................. Tightening Torques 2 ............................................................ Gearbox shafts 3 ............................................................... Shifting diagram 4 ............................................................... Traction gearbox - removal 5 ..................................................... Traction gearbox - disassembly 8 ................................................. Cover -- Removal, Disassembly and assembly 9 .................................. Differential shafts and differential -- Removal 11 ................................... Differential shaft -- D/A 15 ...................................................... Selector shaft -- Removal 16 .................................................... Drive shaft -- Removal 17 ....................................................... Input shaft -- Removal. 19 ...................................................... Shifting disc and shifting drive gear - Removal 23 .................................. Differential - D./A. 28 ............................................................. Drive shaft - D./A. 33 ............................................................. Input shaft - D./A. 38 ............................................................. Traction gearbox - Assembly 43 ....................................................

6 CONTENTS 604.64.971.00 - 07 - 2003 Shifting disc and shifting drive gear - Installation 43 ................................ Input shaft - Installation 46 ...................................................... Drive shaft -- Installation 49 ..................................................... Selector shaft -- Installation 51 .................................................. Differential half shafts and differential -- Installation 51 .............................. Cover -- Installation 53 ......................................................... 25 - FRONT MECHANICAL DRIVE Chapter 1 -- Planetary final drives Specifications 2 ................................................................ Tightening Torques 2 ............................................................ Gearbox Shafts 3 ............................................................... Wheel Bolt - Replacement 4 ...................................................... Planetary Final Drive - Removal/Installation 5 ....................................... Planetary Final Drive - Disassembly/Assembly 7 .................................... Chapter 2 -- 11/111 Final drives Specifications 2 ................................................................ Tightening Torques 2 ............................................................ Special Tools 2 ................................................................. Wheel Bolt -- Replacement 5 ..................................................... Final Drive Removal 6 ........................................................... Final Drive Assembly 10 ......................................................... Final Drive Installation 15 ........................................................ 29 - HYDROSTATIC SYSTEM Chapter 1 - Hydrostatic Drive System Introduction Specifications 2 ................................................................ Introduction 5 .................................................................. Hydrostatic Drive Schematic 7 .................................................... Explanation of Hydraulic Symbols 9 ............................................... Chapter 2 - Hydrostatic System Operation Hydrostatic System Operation 2 .................................................. Multi Function Valves 8 .......................................................... Servo Valve 12 ................................................................. Hydrostatic Drive Motor Valves 14 ................................................. Oil Cooler Bypass Valve 16 ...................................................... Hydrostatic Pump and Drive Motor Identification Numbers 17 ......................... Hydrostatic Pump 19 ............................................................ Hydrostatic Drive Motor 22 .......................................................

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New Holland CR960, CR980 Service Manual

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