NEW HOLLAND
CS520
CS540
CS640
CS660
CL560
REPAIRMANUAL
CL560
CS520
CS540
CS640
CS660
INTRODUCTION
DISTRIBUTIONSYSTEMSA
POWERPRODUCTIONB POWERTRAINC
TRAVELLINGD
BODYANDSTRUCTURE E
FRAMEPOSITIONINGF
TOOLPOSITIONINGG
CROPPROCESSINGK
Foreword(-A.10.A.40)
CS540,CS640,CS520,CS660,CL560
Safetyrules(-A.50.A.10)
CS540,CS640,CS520,CS660,CL560
Drivelineoverview(-A.50.A.51)
CS540,CS640,CS520,CS660,CL560
Basicinstructions(-A.90.A.05)
CS540,CS640,CS520,CS660,CL560
Torque(-A.90.A.10)
CS540,CS640,CS520,CS660,CL560
Conversionfactors(-A.92.A.21)
CS540,CS640,CS520,CS660,CL560
Productidentification(-A.80.A.10)
CS540,CS640,CS520,CS660,CL560
Foreword(-A.10.A.40)
CS540,CS640,CS520,CS660,CL560
TechnicalInformation
Thismanualhasbeenproducedbyanewtechnicalinformationsystem.Thisnewsystemisdesignedtodeliver technicalinformationelectronicallythroughCDROMandinpapermanuals.AcodingsystemcalledICEhasbeen developedtolinkthetechnicalinformationtootherProductSupportfunctionse.g.Warranty.
Technicalinformationiswrittentosupportthemaintenanceandserviceofthefunctionsorsystemsonacustomers machine.Whenacustomerhasaconcernonhismachineitisusuallybecauseafunctionorsystemonhismachine isnotworkingatall,isnotworkingefficiently,orisnotrespondingcorrectlytohiscommands.Whenyourefertothe technicalinformationinthismanualtoresolvethatcustomersconcern,youwill findalltheinformationclassified usingthenewICEcoding,accordingtothefunctionsorsystemsonthatmachine.Onceyouhavelocatedthe technicalinformationforthatfunctionorsystemthenyouwill findallthemechanical,electricalorhydraulicdevices, components,assembliesandsubassembliesforthatfunctionorsystem.Youwillalso findallthetypesofinformation thathavebeenwrittenforthatfunctionorsystem,thetechnicaldata(specifications),thefunctionaldata(howit works),thediagnosticdata(faultcodesandtroubleshooting)andtheservicedata(remove,installadjust,etc.).
ByintegratingthisnewICEcodingintotechnicalinformation,youwillbeabletosearchandretrievejusttheright pieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhismachine.Thisismadepossibleby attaching3categoriestoeachpieceoftechnicalinformationduringtheauthoringprocess.
The firstcategoryistheLocation,thesecondcategoryistheInformationTypeandthethirdcategoryistheProduct:
• LOCATION-isthecomponentorfunctiononthemachine,thatthepieceoftechnicalinformationisgoingto describee.g.Fueltank.
• INFORMATIONTYPE-isthepieceoftechnicalinformationthathasbeenwrittenforaparticularcomponentor functiononthemachinee.g.CapacitywouldbeatypeofTechnicalDatathatwoulddescribetheamount offuelheldbytheFueltank.
• PRODUCT-isthemodelthatthepieceoftechnicalinformationiswrittenfor.
Everypieceoftechnicalinformationwillhavethose3categoriesattachedtoit.Youwillbeabletouseany combinationofthosecategoriesto findtherightpieceoftechnicalinformationyouneedtoresolvethatcustomers concernonhismachine.
Thatinformationcouldbe:
• thedescriptionofhowtoremovethecylinderhead
• atableofspecificationsforahydraulicpump
• afaultcode
• atroubleshootingtable
• aspecialtool
HowtoUsethisManual
ThismanualisdividedintoSections.EachSectionisthendividedintoChapters.Contentspagesareincludedat thebeginningofthemanual,theninsideeverySectionandinsideeveryChapter.AnalphabeticalIndexisincluded attheendofaChapter.Pagenumberreferencesareincludedforeverypieceoftechnicalinformationlistedin theChapterContentsorChapterIndex.
EachChapterisdividedintofourInformationtypes:
• TechnicalData(specifications)forallthemechanical,electricalorhydraulicdevices,componentsand, assemblies.
• FunctionalData(howitworks)forallthemechanical,electricalorhydraulicdevices,componentsand assemblies.
• DiagnosticData(faultcodes,electricalandhydraulictroubleshooting)forallthemechanical,electricalor hydraulicdevices,componentsandassemblies.
• Servicedata(removedisassembly,assemble,install)forallthemechanical,electricalorhydraulicdevices, componentsandassemblies.
Sections
Sectionsaregroupedaccordingtothemainfunctionsorasystemsonthemachine.EachSectionisidentifiedby aletterA,B,Cetc.TheamountofSectionsincludedinthemanualwilldependonthetypeandfunctionofthe machinethatthemanualiswrittenfor.EachSectionhasaContentspagelistedinalphabetic/numericorder.This tableillustrateswhichSectionscouldbeincludedinamanualforaparticularproduct.
SECTION A-DistributionSystems B-PowerProduction C-PowerTrain D-Travelling E-BodyandStructure F-FramePositioning G-ToolPositioning H-WorkingArm J-ToolsandCouplers K-CropProcessing L-FieldProcessing
PRODUCT
TractorsXXXXXXXX
Vehicleswithworkingarms:backhoes, excavators,skidsteers,..... XXXXXXXXX Combines,forageharvesters,balers,.... XXXXXXXXXX Seeding,planting, floating,spraying equipment,.... XXXXXXXXX
Mountedequipmentandtools,.....XXXX
INTRODUCTION
ThismanualcontainstheseSections.ThecontentsofeachSectionareexplainedoverthefollowingpages.
Contents
INTRODUCTION
SectionContents
SECTIONA,DISTRIBUTIONSYSTEMS
ThisSectioncoversthemainsystemsthatinteractwithmostofthefunctionsoftheproduct.Itincludesthecentral partsofthehydraulic,electrical,electronic,pneumatic,lightingandgreaselubricationsystems.Thecomponents thatarededicatedtoaspecificfunctionarelistedintheChapterwhereallthetechnicalinformationforthatfunction isincluded.
SECTIONB,POWERPRODUCTION
ThisSectioncoversallthefunctionsrelatedtotheproductionofpowertomovethemachineandtodrivevarious devices.
SECTIONC,POWERTRAIN
ThisSectioncoversallthefunctionsrelatedtothetransmissionofpowerfromtheenginetotheaxlesandtointernal orexternaldevicesandadditionalProcessDrivefunctions.
SECTIOND,TRAVELLING
ThisSectioncoversallthefunctionsrelatedtomovingthemachine,includingtracks,wheels,steeringandbraking. Itcoversalltheaxlesbothdrivenaxlesandnon-drivenaxles,includinganyaxlesuspension.
SECTIONE,BODYANDSTRUCTURE
ThisSectioncoversallthemainfunctionsandsystemsrelatedtothestructureandbodyofthemachine.Including theframe,theshields,theoperator’scabandtheplatform.
SECTIONG,TOOLPOSITIONING
ThisSectioncoversallthefunctionsrelatedtothe finaland/orautomaticpositioningofthetooloncethetoolis positionedusingtheWorkingArmorthemachineframe.
SECTIONK,CROPPROCESSING
ThisSectioncoversallthefunctionsrelatedtocropprocessing.
INTRODUCTION
Chapters
EachChapterisidentifiedbyaletterandnumbercombinatione.g.EngineB.10.AThe firstletterisidenticaltothe Sectionletteri.e.ChapterB.10isinsideSectionB,PowerProduction. CONTENTS
TheChapterContentslistsallthetechnicaldata(specifications),functionaldata(howitworks),servicedata (remove,installadjust,etc..)anddiagnosticdata(faultcodesandtroubleshooting)thathavebeenwritteninthat Chapterforthatfunctionorsystemonthemachine.
Contents
TECHNICALDATA
POWERPRODUCTION
ENGINE_10.A
ENGINE-Generalspecification(B.10.A-D.40.A.10)
CS540
FUNCTIONALDATA
ENGINE-Dynamicdescription(B.10.A-C.30.A.10)
CS540 SERVICE
ENGINE-Remove(B.10.A-F.10.A.10)
CS540
DIAGNOSTIC
ENGINE-Troubleshooting(B.10.A-G.40.A.10)
CS540
INDEX
TheChapterIndexlistsinalphabeticalorderallthetypesofinformation(calledInformationUnits)thathavebeen writteninthatChapterforthatfunctionorsystemonthemachine.
Index
POWERPRODUCTION-B ENGINE
ENGINE-Dynamicdescription(B.10.A-C.30.A.10)
CS540
ENGINE-Generalspecification(B.10.A-D.40.A.10)
CS540
ENGINE-Remove(B.10.A-F.10.A.10)
CS540
ENGINE-Troubleshooting(B.10.A-G.40.A.10)
CS540
InformationUnitsandInformationSearch
Eachchapteriscomposedofinformationunits.EachinformationunithastheICEcodeshowninparentheseswhich indicatesthefunctionandthetypeofinformationwritteninthatinformationunit.Eachinformationunithasapage referencewithinthatChapter.Theinformationunitsprovideaquickandeasywayto findjusttherightpieceof technicalinformationyouarelookingfor.
exampleinformationunitStackvalve-SectionalView(A.10.A.18-C.10.A.30)
InformationUnitICEcode A10.A18 C 10.A.30
ICEcodeclassification Distribution systems Primary hydraulic power
Navigatetothecorrectinformationunityouaresearchingforbyidentifyingthefunctionandinformationtype fromtheICEcode.
• (1) Functionand (2) Informationtype.
• (A) correspondstothesectionsoftherepairmanual.
(B) correspondstothechaptersoftherepairmanual.
(C) correspondstothetypeofinformationlistedinthechaptercontents,Technicaldata,FunctionalData, DiagnosticorService.
(A) and (B) arealsoshowninthepagenumberingonthepagefooter. THERESTOFTHECODINGISNOTLISTEDINALPHANUMERICORDERINTHISMANUAL.
• Youwill findatableofcontentsatthebeginningandendofeachsectionandchapter. Youwill findanalphabeticalindexattheendofeachchapter.
• Byreferringto (A), (B) and (C) ofthecoding,youcanfollowthecontentsorindex(pagenumbers)andquickly findtheinformationyouarelookingfor.
PageHeaderandFooter
Thepageheaderwillcontainthefollowingreferences:
• SectionandChapterdescription
Thepagefooterwillcontainthefollowingreferences:
• PublicationnumberforthatManual,SectionorChapter.
• Versionreferenceforthatpublication.
• Publicationdate
• Section,chapterandpagereferencee.g.A.10.A/9
Importantinformation
AllrepairandmaintenanceworkslistedinthismanualmustbecarriedoutonlybystaffbelongingtotheNEW HOLLANDServicenetwork,strictlycomplyingwiththeinstructionsgivenandusing,wheneverrequired,thespecial tools.
Anyonewhocarriesouttheaboveoperationswithoutcomplyingwiththeprescriptionsshallberesponsiblefor thesubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regionalor localdealers,rejectanyresponsibilityfordamagesduetotheanomalousbehaviourofpartsand/orcomponentsnot approvedbythemanufacturerhimself,includingthoseusedfortheservicingorrepairoftheproductmanufactured ormarketedbytheManufacturer.Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedor marketedbytheManufacturerincaseofdamagesduetoananomalousbehaviourofpartsand/orcomponentsnot approvedbytheManufacturer.
Safetyrules(-A.50.A.10)
CS540,CS640,CS520,CS660,CL560
WARNINGANDDANGERSYMBOL
Thiswarningsymbolpointsoutimportantpersonalsafetymessages. Carefullyreadthefollowingsafetyregulationsandobserveadvised precautionsinordertoavoidpotentialhazardsandsafeguardyourhealth andsafety.Inthismanualthesymbolisaccompaniedbythefollowing keywords:
WARNING-Warningsconcerningunsuitablerepairoperationsthatmay jeopardisethesafetyofRepairpersonnel.
DANGER-Specificwarningsconcerningpotentialhazardsforoperator safetyorforotherpersonsdirectlyorindirectlyinvolved.
ACCIDENTPREVENTION
Mostaccidentsorinjuriesthatoccurinworkshopsaretheresultofnon-observanceofsimpleandfundamental safetyregulations.Forthisreason,INMOSTCASESTHESEACCIDENTSCANBEAVOIDEDbyforeseeing possiblecausesandconsequentlyactingwiththenecessarycautionandcare.
Accidentsmayoccurwithalltypesofmachine,regardlessofhowwellthemachineinquestionwasdesigned andbuilt.
Acarefulandjudiciousservicetechnicianisthebestguaranteeagainstaccidents.
Preciseobservanceofthemostbasicsafetyruleisnormallysufficienttoavoidmanyseriousaccident
DANGER
M871-Shutdownthemachine,removekey,besureallmovingpartshavestoppedandallpressureinthe systemsisrelievedbeforecleaning,adjustingorlubricatingtheequipment.
SAFETYRULES
Generalguidelines
• Carefullyfollowspecifiedrepairandmaintenanceprocedures.
• Donotwearrings,wristwatches,jewellery,unbuttonedorloosearticlesofclothingsuchas:ties,tornclothing, scarves,openjacketsorshirtswithopenzipsthatmayremainentangledinmovingparts.Itisadvisedtowear approvedsafetyclothing,e.g.:non-slipfootwear,gloves,safetygoggles,helmets,etc.
• Donotcarryoutrepairoperationswithsomeonesittinginthedriver’sseat,unlessthepersonisatrained technicianwhoisassistingwiththeoperationinquestion.
• Donotoperatethemachineoruseanyoftheimplementsfromdifferentpositions,otherthanthedriver’sseat.
• Donotcarryoutoperationsonthemachinewiththeenginerunning,unlessspecificallyindicated.
• Stoptheengineandcheckthatthehydrauliccircuitsarepressure-freebeforeremovingcaps,covers, valves,etc.
• Allrepairandmaintenanceoperationsmustbecarriedoutusingextremecareandattention.
• Servicestepsandplatformsusedintheworkshoporelsewhereshouldbebuiltaccordingtostandardaccident preventionregulations.
• Disconnectthep.t.o.fromtheandlabelallcontrolstoindicatethatthemachineisbeingserviced.Any partsthataretoberaisesmustbelockedinposition.
• Brakesareinoperativewhenmanuallyreleasedforrepairormaintenancepurposes.Useblocksorsimilar devicestocontrolthemachineintheseconditions.
• Onlyusespecifiedtowingpointsfortowingthemachine.Connectpartscarefully.Makesurethatallpins and/orlocksaresecuredinpositionbeforeapplyingtraction.Neverremainnearthetowingbars,cables orchainsthatareoperatingunderload.
INTRODUCTION
• Whenloadingorunloadingthemachinefromthetrailer(orothermeansoftransport),selecta flatarea capableofsustainingthetrailerortruckwheels.Firmlysecurethemachinetothetruckortrailerandlockthe wheelsinthepositionusedbythecarrier.
• Electricheaters,battery-chargersandsimilarequipmentmustonlybepoweredbyauxiliarypowersupplies withefficientgroundinsulationtoavoidelectricalshockhazards.
• Alwaysusesuitablehoistingorliftingdeviceswhenraisingormovingheavyparts.
• Takeextracareifbystandersarepresent.
• Neverusegasoline,dieseloilorotherinflammableliquidsascleaningagents.Usenon-inflammable,non toxiccommerciallyavailablesolvents.
• Wearsafetygoggleswithsideguardswhencleaningpartswithcompressedair.
• Reducetheairpressureaccordingtothelocalregulationsinforce.
• Donotruntheengineinconfinedspaceswithoutsuitableventilation.
• Neverusenaked flamesforlightingwhenworkingonthemachineorcheckingforleaks.
• Allmovementsmustbecarriedoutcarefullywhenworkingunder,onornearthemachine.Wearprotective equipment:helmets,gogglesandspecialfootwear.
• Whencarryingoutcheckswiththeenginerunning,requesttheassistanceofanoperatorinthedriver’sseat. Theoperatormustmaintainvisualcontactwiththeservicetechnicianatalltimes.
• Ifoperatingoutsidetheworkshop,positionthemachineona flatsurfaceandlockinposition.Ifworkingona slope,lockthemachineinposition.Movetoa flatareaassoonasissafelypossible.
• Damagedorbentchainsorcablesareunreliable.Donotusethemforliftingortowing.Alwaysusesuitable protectivegloveswhenhandlingchainsorcables.
• Chainsshouldalwaysbesafelysecured.Makesurethatthehitch-uppointiscapableofsustainingtheloadin question.Keeptheareanearthehitch-uppoint,chainsorcablesfreeofallbystanders.
• MaintenanceandrepairoperationsmustbecarriedoutinaCLEANandDRYarea.Eliminateanywateror oilspillageimmediately.
• Donotcreatepilesofoilorgrease-soakedragsastheyrepresentaserious firehazard.Alwaysstorerags inaclosedmetalcontainer.Beforeengagingthemachine,makesurethattherearenopersonswithinthe machineorimplementrangeofaction.
• Emptyyourpocketsofallobjectsthatmayfallaccidentallyunobservedintothemachineinnercompartments.
• Inthepresenceofprotrudingmetalparts,useprotectivegogglesorgoggleswithsideguards,helmets, specialfootwearandgloves.
• Whenwelding,useprotectivesafetydevices:tintedsafetygoggles,helmets,specialoveralls,glovesand footwear.Allpersonspresentintheareawhereweldingistakingplacemustweartintedgoggles.NEVER LOOKDIRECTLYATTHEWELDINGARCWITHOUTSUITABLEEYEPROTECTION.
• Metalcablestendtofraywithrepeateduse.Alwaysusesuitableprotectivedevices(gloves,goggles,etc.) whenhandlingcables.
• Handleallpartscarefully.Donotputyourhandsor fingersbetweenmovingparts.Wearsuitablesafety clothing-safetygoggles,glovesandshoes.
INTRODUCTION
Start-up
• Neverruntheengineinconfinedspacesthatarenotequippedwithadequateventilationforexhaustgas extraction.
• Neverplacethehead,body,limbs,feet,handsor fingersnearrotatingandmovingparts.
Hydraulicsystems
• Aliquidleakingfromatinyholemaybealmostinvisiblebut,atthesametime,bepowerfulenoughtopenetrate theskin.Therefore,NEVERUSEHANDSTOCHECKFORLEAKSbutuseapieceofcardboardorwoodfor thispurpose.Ifanyliquidpenetratesskintissue,callformedicalaidimmediately.Failuretotreatthiscondition withcorrectmedicalproceduremayresultinseriousinfectionordermatosis.
• Inordertocheckthepressureinthesystemusesuitableinstruments.
WheelsandTyres
• Makesurethatthetyresarecorrectlyinflatedatthepressurespecifiedbythemanufacturer.Periodically checktherimsandtyresfordamage.
• Standawayfrom(atthesideof)thetyrewhencheckinginflationpressure.
• Donotusepartsofrecoveredwheelsasincorrectweldingbrazingorheatingmayweakenandeventually causedamagetothewheel.
• Nevercutorweldarimmountedwithaninflatedtyre.
• Toremovethewheels,lockallwheels.Afterhavingraisedthemachine,positionsupportsunderneath, accordingtoregulationsinforce.
• Deflatethetyrebeforeremovinganyobjectsthatmaybejammedinthetyretread.
• Neverinflatetyresusinginflammablegases,asthismayresultinexplosionsandinjurytobystanders.
RemovalandRe-fitting
• Liftandhandleallheavypartsusingsuitablehoistingequipment.Makesurethatpartsaresustainedby appropriatehooksandslings.Usethehoistingeyeboltsforliftingoperations.Extracareshouldbetakenif personsarepresentneartheloadtobelifted.
• Handleallpartscarefully.Donotputyourhandsor fingersbetweenparts.Wearsuitablesafetyclothingsafetygoggles,glovesandshoes.
• Avoidtwistingchainsormetalcables.Alwayswearsafetygloveswhenhandlingcablesorchains.
Drivelineoverview(-A.50.A.51)
CS540,CS640,CS520,CS660,CL560
MAINOUTPUTSHAFT
1.Engine
2.Rotarydustscreen
3.Chaffspreaderdriveshaft(Ifinstalled)
