CS Repair Manual 604.64.981.00

REPAIR MANUAL
CS540
CS640
CS520
CS660
604_64_981_00 1 02/07/2004
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
POWER TRAIN C
TRAVELLING D
BODY AND STRUCTURE E
TOOL POSITIONING G
CROP PROCESSING K
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INTRODUCTION
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1
Contents
INTRODUCTION
Foreword ( - A.10.A.40) 3
CS540, CS640, CS520, CS660
Safety rules ( - A.50.A.10) 9
CS540, CS640, CS520, CS660
Driveline overview ( - A.50.A.51) 12
CS540, CS640, CS520, CS660
Basic instructions ( - A.90.A.05) 16
CS540, CS640, CS520, CS660
Torque ( - A.90.A.10) 19
CS540, CS640, CS520, CS660
Conversion factors ( - A.92.A.21) 22
CS540, CS640, CS520, CS660
Product identification ( - A.80.A.10) 23
CS540, CS640, CS520, CS660
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INTRODUCTION
Foreword ( - A.10.A.40)
CS540, CS640, CS520, CS660
Technical Information
This manual has been produced by a new technical information system. This new system is designed to deliver
technical information electronically through CDROM and in paper manuals. A coding system called ICE has been
developed to link the technical information to other Product Support functions e.g. Warranty.
Technical information is written to support the maintenance and service of the functions or systems on a customers
machine. When a customer has a concern on his machine it is usually because a function or system on his machine
is not working at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the
technical information in this manual to resolve that customers concern, you will find all the information classified
using the new ICE coding, according to the functions or systems on that machine. Once you have located the
technical information for that function or system then you will find all the mechanical, electrical or hydraulic devices,
components, assemblies and sub assemblies for that function or system. You will also find all the types of information
that have been written for that function or system, the technical data (specifications), the functional data (how it
works), the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.).
By integrating this new ICE coding into technical information , you will be able to search and retrieve just the right
piece of technical information you need to resolve that customers concern on his machine. This is made possible by
attaching 3 categories to each piece of technical information during the authoring process.
The first category is the Location, the second category is the Information Type and the third category is the Product:
• LOCATION - is the component or function on the machine, that the piece of technical information is going to
describe e.g. Fuel tank.
• INFORMATION TYPE - is the piece of technical information that has been written for a particular component or
function on the machine e.g. Capacity would be a type of Technical Data that would describe the amount
of fuel held by the Fuel tank.
• PRODUCT - is the model that the piece of technical information is written for.
Every piece of technical information will have those 3 categories attached to it. You will be able to use any
combination of those categories to find the right piece of technical information you need to resolve that customers
concern on his machine.
That information could be:
• the description of how to remove the cylinder head
• a table of specifications for a hydraulic pump
• a fault code
• a troubleshooting table
• a special tool
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INTRODUCTION
How to Use this Manual

This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at
the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included
at the end of a Chapter. Page number references are included for every piece of technical information listed in
the Chapter Contents or Chapter Index.
Each Chapter is divided into four Information types:
• Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components and,
assemblies.
• Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components and
assemblies.
• Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or
hydraulic devices, components and assemblies.
• Service data (remove disassembly, assemble, install) for all the mechanical, electrical or hydraulic devices,
components and assemblies.
Sections
Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by
a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the
machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This
table illustrates which Sections could be included in a manual for a particular product.
SECTION
A - Distribution Systems
B - Power Production
C - Power Train
D - Travelling
E - Body and Structure
F - Frame Positioning
G - Tool Positioning
H - Working Arm
J - Tools and Couplers
K - Crop Processing
L - Field Processing
PRODUCT
Tractors X X X X X X X X
Vehicles with working arms: backhoes, X X X X X X X X X
excavators, skid steers, .....
Combines, forage harvesters, balers, .... X X X X X X X X X X
Seeding, planting, floating, spraying X X X X X X X X X
equipment, ....
Mounted equipment and tools, ..... X X X X
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INTRODUCTION
This manual contains these Sections. The contents of each Section are explained over the following pages.
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
POWER TRAIN C
TRAVELLING D
BODY AND STRUCTURE E
TOOL POSITIONING G
CROP PROCESSING K
Section Contents
SECTION A, DISTRIBUTION SYSTEMS
This Section covers the main systems that interact with most of the functions of the product. It includes the central
parts of the hydraulic, electrical, electronic, pneumatic, lighting and grease lubrication systems. The components
that are dedicated to a specific function are listed in the Chapter where all the technical information for that function
is included.
SECTION B, POWER PRODUCTION

This Section covers all the functions related to the production of power to move the machine and to drive various
devices.
SECTION C, POWER TRAIN

This Section covers all the functions related to the transmission of power from the engine to the axles and to internal
or external devices and additional Process Drive functions.
SECTION D, TRAVELLING
This Section covers all the functions related to moving the machine, including tracks, wheels, steering and braking.
It covers all the axles both driven axles and non-driven axles, including any axle suspension.
SECTION E, BODY AND STRUCTURE

This Section covers all the main functions and systems related to the structure and body of the machine. Including
the frame, the shields, the operator’s cab and the platform.
SECTION G, TOOL POSITIONING

This Section covers all the functions related to the final and/or automatic positioning of the tool once the tool is
positioned using the Working Arm or the machine frame.
SECTION K, CROP PROCESSING

This Section covers all the functions related to crop processing.
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INTRODUCTION
Chapters
Each Chapter is identified by a letter and number combination e.g. Engine B.10.A The first letter is identical to the
Section letter i.e. Chapter B.10 is inside Section B, Power Production.
CONTENTS
The Chapter Contents lists all the technical data (specifications), functional data (how it works), service data
(remove, install adjust, etc..) and diagnostic data (fault codes and troubleshooting) that have been written in that
Chapter for that function or system on the machine.
Contents
POWER PRODUCTION
ENGINE _ 10.A
TECHNICAL DATA
ENGINE - General specification (B.10.A - D.40.A.10)
CS540
FUNCTIONAL DATA
ENGINE - Dynamic description (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
The Chapter Index lists in alphabetical order all the types of information (called Information Units) that have been
written in that Chapter for that function or system on the machine.
Index
POWER PRODUCTION - B
ENGINE
ENGINE - Dynamic description (B.10.A - C.30.A.10)
CS540
CS540
ENGINE - Remove (B.10.A - F.10.A.10)
CS540
CS540
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INTRODUCTION
Information Units and Information Search

Each chapter is composed of information units. Each information unit has the ICE code shown in parentheses which
indicates the function and the type of information written in that information unit. Each information unit has a page
reference within that Chapter. The information units provide a quick and easy way to find just the right piece of
technical information you are looking for.
example information unit Stack valve - Sectional View (A.10.A.18 - C.10.A.30)

Information Unit ICE code A 10.A 18 C 10.A.30
ICE code classification Distribution Primary Stack valve Functional Sectional view
systems hydraulic data
power
CRIL03J033E01 1
Navigate to the correct information unit you are searching for by identifying the function and information type
from the ICE code.
• (1) Function and (2) Information type.
• (A) corresponds to the sections of the repair manual.

(B) corresponds to the chapters of the repair manual.
(C) corresponds to the type of information listed in the chapter contents, Technical data, Functional Data,
Diagnostic or Service.
(A) and (B) are also shown in the page numbering on the page footer.
THE REST OF THE CODING IS NOT LISTED IN ALPHANUMERIC ORDER IN THIS MANUAL.
• You will find a table of contents at the beginning and end of each section and chapter.
You will find an alphabetical index at the end of each chapter.
• By referring to (A), (B) and (C) of the coding, you can follow the contents or index (page numbers) and quickly
find the information you are looking for.
Page Header and Footer

The page header will contain the following references:
• Section and Chapter description
The page footer will contain the following references:
• Publication number for that Manual, Section or Chapter.
• Version reference for that publication.
• Publication date
• Section, chapter and page reference e.g. A.10.A / 9
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INTRODUCTION
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,
regional 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 manufactured or marketed by the Manufacturer. In any case, no warranty is given or attributed on the
product manufactured or marketed by the Manufacturer in case of damages due to an anomalous behaviour of parts
and/or components not approved by the Manufacturer.
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INTRODUCTION
Safety rules ( - A.50.A.10)

CS540, CS640, CS520, CS660
WARNING AND DANGER SYMBOL

This warning symbol points out important personal safety messages.
Carefully read the following safety regulations and observe advised
precautions in order to avoid potential hazards and safeguard your health
and safety. In this manual the symbol is accompanied by the following
key words:
WARNING - Warnings concerning unsuitable repair operations that may
jeopardise the safety of Repair personnel.
DANGER - Specific warnings concerning potential hazards for operator
safety or for other persons directly or indirectly involved.
ACCIDENT PREVENTION
Most accidents or injuries that occur in workshops are the result of non-observance of simple and fundamental
safety regulations. For this reason, IN MOST CASES THESE ACCIDENTS CAN BE AVOIDED by foreseeing
possible causes and consequently acting with the necessary caution and care.
Accidents may occur with all types of machine, regardless of how well the machine in question was designed
and built.
A careful and judicious service technician is the best guarantee against accidents.
Precise observance of the most basic safety rule is normally sufficient to avoid many serious accident
DANGER
M871 - Shut down the machine, remove key, be sure all moving parts have stopped and all pressure in the
systems is relieved before cleaning, adjusting or lubricating the equipment.
SAFETY RULES
General guidelines
• Carefully follow specified repair and maintenance procedures.
• Do not wear rings, wristwatches, jewellery, unbuttoned or loose articles of clothing such as: ties, torn clothing,
scarves, open jackets or shirts with open zips that may remain entangled in moving parts. It is advised to wear
approved safety clothing, e.g.: non-slip footwear, gloves, safety goggles, helmets, etc.
• Do not carry out repair operations with someone sitting in the driver’s seat, unless the person is a trained
technician who is assisting with the operation in question.
• Do not operate the machine or use any of the implements from different positions, other than the driver’s seat.
• Do not carry out operations on the machine with the engine running, unless specifically indicated.
• Stop the engine and check that the hydraulic circuits are pressure-free before removing caps, covers,
valves, etc.
• All repair and maintenance operations must be carried out using extreme care and attention.
• Service steps and platforms used in the workshop or elsewhere should be built according to standard accident
prevention regulations.
• Disconnect the p.t.o. from the and label all controls to indicate that the machine is being serviced. Any
parts that are to be raises must be locked in position.
• Brakes are inoperative when manually released for repair or maintenance purposes. Use blocks or similar
devices to control the machine in these conditions.
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INTRODUCTION
• Only use specified towing points for towing the machine. Connect parts carefully. Make sure that all pins
and/or locks are secured in position before applying traction. Never remain near the towing bars, cables or
chains that are operating under load.
• When loading or unloading the machine from the trailer (or other means of transport), select a flat area
capable of sustaining the trailer or truck wheels. Firmly secure the machine to the truck or trailer and lock the
wheels in the position used by the carrier.
• Electric heaters, battery-chargers and similar equipment must only be powered by auxiliary power supplies
with efficient ground insulation to avoid electrical shock hazards.
• Always use suitable hoisting or lifting devices when raising or moving heavy parts.
• Take extra care if bystanders are present.
• Never use gasoline, diesel oil or other inflammable liquids as cleaning agents. Use non-inflammable, non
toxic commercially available solvents.
• Wear safety goggles with side guards when cleaning parts with compressed air.
• Reduce the air pressure according to the local regulations in force.
• Do not run the engine in confined spaces without suitable ventilation.
• Never use naked flames for lighting when working on the machine or checking for leaks.
• All movements must be carried out carefully when working under, on or near the machine. Wear protective
equipment: helmets, goggles and special footwear.
• When carrying out checks with the engine running, request the assistance of an operator in the driver’s seat.
The operator must maintain visual contact with the service technician at all times.
• If operating outside the workshop, position the machine on a flat surface and lock in position. If working on a
slope, lock the machine in position. Move to a flat area as soon as is safely possible.
• Damaged or bent chains or cables are unreliable. Do not use them for lifting or towing. Always use suitable
protective gloves when handling chains or cables.
• Chains should always be safely secured. Make sure that the hitch-up point is capable of sustaining the load in
question. Keep the area near the hitch-up point, chains or cables free of all bystanders.
• Maintenance and repair operations must be carried out in a CLEAN and DRY area. Eliminate any water or
oil spillage immediately.
• Do not create piles of oil or grease-soaked rags as they represent a serious fire hazard. Always store rags
in a closed metal container. Before engaging the machine, make sure that there are no persons within the
machine or implement range of action.
• Empty your pockets of all objects that may fall accidentally unobserved into the machine inner compartments.
• In the presence of protruding metal parts, use protective goggles or goggles with side guards, helmets,
special footwear and gloves.
• When welding, use protective safety devices: tinted safety goggles, helmets, special overalls, gloves and
footwear. All persons present in the area where welding is taking place must wear tinted goggles. NEVER
LOOK DIRECTLY AT THE WELDING ARC WITHOUT SUITABLE EYE PROTECTION.
• Metal cables tend to fray with repeated use. Always use suitable protective devices (gloves, goggles, etc.)
when handling cables.
• Handle all parts carefully. Do not put your hands or fingers between moving parts. Wear suitable safety
clothing - safety goggles, gloves and shoes.
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INTRODUCTION
Start-up
• Never run the engine in confined spaces that are not equipped with adequate ventilation for exhaust gas
extraction.
• Never place the head, body, limbs, feet, hands or fingers near rotating and moving parts.
Hydraulic systems
• A liquid leaking from a tiny hole may be almost invisible but, at the same time, be powerful enough to penetrate
the skin. Therefore, NEVER USE HANDS TO CHECK FOR LEAKS but use a piece of cardboard or wood for
this purpose. If any liquid penetrates skin tissue, call for medical aid immediately. Failure to treat this condition
with correct medical procedure may result in serious infection or dermatosis.
• In order to check the pressure in the system use suitable instruments.
Wheels and Tyres
• Make sure that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically
check the rims and tyres for damage.
• Stand away from (at the side of) the tyre when checking inflation pressure.
• Do not use parts of recovered wheels as incorrect welding brazing or heating may weaken and eventually
cause damage to the wheel.
• Never cut or weld a rim mounted with an inflated tyre.
• To remove the wheels, lock all wheels. After having raised the machine, position supports underneath,
according to regulations in force.
• Deflate the tyre before removing any objects that may be jammed in the tyre tread.
• Never inflate tyres using inflammable gases, as this may result in explosions and injury to bystanders.
Removal and Re-fitting
• Lift and handle all heavy parts using suitable hoisting equipment. Make sure that parts are sustained by
appropriate hooks and slings. Use the hoisting eyebolts for lifting operations. Extra care should be taken
if persons are present near the load to be lifted.
• Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -
safety goggles, gloves and shoes.
• Avoid twisting chains or metal cables. Always wear safety gloves when handling cables or chains.
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INTRODUCTION
Driveline overview ( - A.50.A.51)

CS540, CS640, CS520, CS660
ZDF0405A 1
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INTRODUCTION
MAIN OUTPUT SHAFT

1. Engine
2. Rotary dust screen
3. Chaff spreader drive shaft
4. Chopper intermediate drive shaft
5. Chopper clutch
6. Chopper
7. Chaff spreader
8. Drum variator
9. Drum
10. Beater
11. Hydraulic pump shaft
12. Straw walkers
13. Eccentric shaft
14. Shaker shoe
15. Straw elevator bottom shaft
16. Clean grain cross auger
17. Returns cross auger
18. Fan variator
19. Fan
20. Intermediate shaft
21. Rotary separator
22. Grain elevator
23. Returns top auger
24. Straw elevator top shaft
25. Header drive shaft
26. Straw elevator chain
27. Grain tank filling auger
28. Returns elevator
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INTRODUCTION
UNLOADING OUTPUT SHAFT
ZDA7490A 2
1. Engine
2. Rotary dust screen
3. Unloading intermediate drive shaft
4. Grain tank bottom auger
5. Unloading auger
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INTRODUCTION
ENGINE
- Rotary dust screen intermediate shaft
-- Rotary dust screen
- Air conditioning compressor
- Air compressor
- Ventilator
- Water pump
- Alternator
- Hydraulic pump
- Hydrostatic pump
- Unloading output shaft
-- Unloading intermediate shaft
--- Unloading bottom auger
---- Unloading tube auger
- Chopper intermediate drive shaft (clutch)
-- Chopper
- Main output shaft
-- Intermediate shaft
--- High speed drum variator
---- Beater
-----Drum
--- Eccentric shaft (Shaker shoe)
---- Straw walkers
----- Chaff spreader
---- Clean grain cross auger
----- Grain elevator
------ Clean grain tank filling auger
----- Returns cross bottom auger
------ Returns elevator
------- Returns cross top auger
--- Rotary separator (If installed)
--- Cleaning fan variator
---- Cleaning fan
--- Straw elevator top shaft
---- Header drive shaft
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INTRODUCTION
Basic instructions ( - A.90.A.05)

CS540, CS640, CS520, CS660
SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up
the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated
value indicated on each 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.
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INTRODUCTION
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.
4. Always disconnect the negative cable from the battery when charging the battery in the combine with a
battery charger.
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.
WARNING
84-110 - Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or
clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg or vegetables oil. Call physician immediately. EYES: flush with water
for 15 minutes and get prompt medical attention.
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INTRODUCTION
SPARE PARTS
Only use original NEW HOLLAND spare parts bearing the logo shown below.
geninfo_03 1
Only genuine spare parts guarantee the same quality, duration and safety as original parts, as they are the same
parts that are assembled during standard production. Only NEW HOLLAND genuine spare parts can offer this
guarantee. When ordering spare parts, always provide the following information:
• Machine model (commercial name) and serial number
• part number of the ordered part, which can be found in the "Microfiches" or the "Spare Parts Catalogue",
used for order processing
TOOLS
The tools that NEW HOLLAND suggests and illustrate in this manual have been:
• specifically researched and designed for use with NEW HOLLAND machines
• essential for reliable repair operations
• accurately built and rigorously tested so as to offer efficient and long-lasting operation
By using these tools, Repair Personnel will benefit from:
• operating in optimal technical conditions
• obtaining the best results
• saving time and effort
• working in safe conditions

NOTE: Wear limit values indicated for certain parts should be considered to be recommended, but not binding. The
terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from the rear,
facing in the direction of travel of the machine during operation.
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INTRODUCTION
Torque ( - A.90.A.10)
CS540, CS640, CS520, CS660
geninfo_05 1
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INTRODUCTION
geninfo_06 2
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INTRODUCTION
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INTRODUCTION
Conversion factors ( - A.92.A.21)

CS540, CS640, CS520, CS660
Linear
1 mm = 0.03937 in 1 in = 25.4 mm
1 Km = 0.6214 miles 1 mile = 1.6093 km
1m = 3.281 ft 1 ft = 0.3048 m
Area
1 ha = 2.471 acre 1 acre = 0.4047 ha
Volume
1 liter = 0.0063 barrel 1 barrel = 158.987 liter
1 liter = 0.028 US bushel 1 US bushel = 35.2391 liter
1 liter = 0.2642 US gal 1 US gal = 3.7853 liter
1 liter = 1.057 US quart 1 US quart = 0.9464 liter
1 mm³ = 0.061 in³ 1 in³ = 16387 mm³
Weight
1 kg = 2.204 pound 1 pound = 0.4536 kg
Torque
1 Nm = 0.7376 lb.ft 1 lb.ft = 1.3558 Nm
Power
1 kW = 1.358 hp 1 hp = 0.746 kW
Pressure
1 bar = 14.505 psi 1 psi = 0.06894 bar
1 kPa = 0.145 psi 1 psi = 6.894 kPa
1 pa = 10 - 5 bar 1 bar = 100 kPa
Temperature
1 °C = ((1.8 x ° C) + 32) °F 1 °F = (0.56 x (° F - 32)) °C
Flow
1 L/min = 0.2642 US gpm 1 US gpm = 3.7853 L/min
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INTRODUCTION
Product identification ( - A.80.A.10)

CS540, CS640, CS520, CS660
EXPLANATION OF MACHINE SERIAL NUMBERS

Example : n° 281368001
281368001: The first two digits identify the model within a product line:
CS520 = 24
CS540 = 28
CS640 = 29
CS660 = 27
281368001: The third digit indicates the product line. There are 4 product lines in Zedelgem:
CX-CS-TX Combine harvesters: 1

Combine headers: 3
Balers: 4
Forage Harvesters: 5
281368001: These 3 digits indicate the batch in which the machine was made.
281368001: Product line number (1) and batch (368) together form the series number (1368).
281368001: The last 3 digits are a sequential number for each model within a batch.
Summarizing we can say that this machine is the first CS540 of serie 1368.
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INTRODUCTION
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REPAIR MANUAL
DISTRIBUTION SYSTEMS
CS540
CS640
CS520
CS660
12116 1 02/07/2004
A
Contents
DISTRIBUTION SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM A.10.A

CS540, CS640, CS520, CS660
PNEUMATIC SYSTEM A.20.A

CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM A.30.A

CS540, CS640, CS520, CS660
LIGHTING SYSTEM A.40.A

CS540, CS640, CS520, CS660
ELECTRONIC SYSTEM A.50.A

CS540, CS640, CS520, CS660
12116 1 02/07/2004
A
PRIMARY HYDRAULIC POWER SYSTEM - 10.A
CS540
CS640
CS520
CS660
12117 1 02/07/2004
A.10.A / 1
Contents
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - Torque (A.10.A - D.20.A.10) 4

CS540, CS640, CS520, CS660
Hydraulic pump
Hydraulic pump - General specification (A.10.A.20 - D.40.A.10) 6
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (A.10.A - C.20.B.20) 7

CS540, CS640, CS520, CS660
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic symbol (A.10.A - C.20.C.20) 13
CS540, CS640, CS520, CS660
PRIMARY HYDRAULIC POWER SYSTEM - Overview (A.10.A - C.40.B.10) 15
CS540, CS640, CS520, CS660
PRIMARY HYDRAULIC POWER SYSTEM - Component localisation (A.10.A - C.40.B.20) 18
CS540, CS640, CS520, CS660
Relief valve
Relief valve - Static description (A.10.A.16 - C.30.A.20) 22
CS540, CS640, CS520, CS660
Stack valve
Stack valve - Dynamic description (A.10.A.18 - C.30.A.10) 23
CS540, CS640, CS520, CS660
Stack valve - Static description (A.10.A.18 - C.30.A.20) 29
CS540, CS640, CS520, CS660
Hydraulic pump
Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20) 32
CS540, CS640, CS520, CS660
Oil filter
Oil filter - Static description (A.10.A.24 - C.30.A.20) 33
CS540, CS640, CS520, CS660
Breather
Breather - Static description (A.10.A.26 - C.30.A.20) 34
CS540, CS640, CS520, CS660
SERVICE
Stack valve
Stack valve - Remove (A.10.A.18 - F.10.A.10) 35
CS540, CS640, CS520, CS660
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Stack valve - Install (A.10.A.18 - F.10.A.15) 37
CS540, CS640, CS520, CS660
Stack valve - Repair (A.10.A.18 - F.75.C.32) 39
CS540, CS640, CS520, CS660
Hydraulic pump
Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25) 43
CS540, CS640, CS520, CS660
Hydraulic pump - Remove (A.10.A.20 - F.10.A.10) 44
CS540, CS640, CS520, CS660
Hydraulic pump - Install (A.10.A.20 - F.10.A.15) 46
CS540, CS640, CS520, CS660
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Torque (A.10.A -

D.20.A.10)
CS540, CS640, CS520, CS660
Union nuts
55009 1
Ferrules
The ferrule must be pre-assembled on the tube. Tighten the union nut as specified in the table below. The ferrule
and screw thread are greased.
Tube outer diameter mm (inch) Torque Nm (lb.ft)

Minimum Maximum
8 (0.32) 15 (11) 20 (15)
10 (0.4) 25 (18) 30 (22)
12 (0.47) 35 (26) 40 (29)
16 (0.63) 50 (37) 55 (40)
18 (0.71) 60 (44) 70 (51)
22 (0.87) 100 (74) 110 (81)
28 (1.10) 110 (81) 120 (88)
Metric fittings
Unions
Are suitable for use with union nuts and ferrules and ball-type nipples.
55011 2
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Connections
Are screwed in ISO metric thread - tolerance class 6H - with a tightening torque as specified in the table below.
55012 3
Tube outer diameter mm (inch) Torque Nm (lb.ft)

Minimum Maximum
8 (0,32) 40 (29) 45 (33)
10 (0,40) 65 (48) 70 (51)
12 (0,47) 80 (59) 85 (63)
16 (0,63) 100 (74) 120 (88)
18 (0,71) 120 (88) 140 (103)
22 (0,87) 200 (147) 220 (164)
28 (1,10) 350 (257) 380 (280)
Swivel nut with ball-type nipple
Are suitable for use with female unions
55013 4
D1 Torque Nm (lb.ft)
6H Minimum Maximum
M14 x 1.5 - -
M16 x 1.5 15 (11) 20 (15)
M18 x 1.5 20 (15) 25 (18)
M24 x 1.5 30 (22) 35 (26)
M26 x 1.5 - -
M30 x 2 - -
M36 x 2 - -
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Hydraulic pump - General specification (A.10.A.20 - D.40.A.10)

CS540, CS640, CS520, CS660
The hydraulic system contains three hydraulic pumps
ZDF0052A 1
Main hydraulic pump (2)
Type: Silence gear type

Direction of rotation left-hand rotation
Maximum pressure 280 bar (4061 psi)
Maximum speed 3000 rpm
Output per revolution 16.5 cc/rev.
Maximum oil flow 48 l/min (12.7 gal/min)
Hydraulic pump (Steering circuit) (3)
Type: Silence gear type

Output per revolution 5.5 cc/rev.
Hydraulic pump (Lateral flotation circuit) (4) (if installed)
Type: Gear type

Output per revolution 2 cc/rev.
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PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema

(A.10.A - C.20.B.20)
CS540, CS640, CS520, CS660
• 1. Engine
• 2. Pump (main hydraulics)
• 3. Pump (steering circuit)
• 4. Pump (lateral flotation) (If installed)
• 5. Oil reservoir
• 6. Filler cap with filter
• 7. Load sensing valve
• 7a. Pilot line
• 8. Header height control valve
• 8a. Header height control load sensing valve
• 8b. Header height control valve (electromagnetic operation)
• 8c. Pilot line
• 8d. Pilot line
• 8e. High pressure line to the control valves
• 8f. Oil flow restrictor
• 8g. Lockout valve
• 8h. Pressure relief valve
• 8i. Oil flow restrictor
• 9. Header cylinders
• 10. Accumulator control valve
• 11. Header suspension accumulator
• 12. Pressure sensor
• 13. Unloading tube control valve
• 13a. Load sensing lockout valve
• 14. Unloading tube cylinder
• 15. Reel vertical adjustment valve
• 15a. Load sensing lockout valve
• 16. Reel vertical adjustment cylinders
• 17. Reel horizontal adjustment valve
• 17a. Load sensing lock out valve
• 18. Quick-attach coupler or screw couplers
• 19. Non-return valve (single direction restrictor)
• 20. Reel horizontal adjustment cylinders
• 21. Header and straw elevator reversing valve
• 21a. Load sensing lock out valve
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• 22. Screw couplers with non return valve
• 23. Header and straw elevator reversing motor
• 24. Steering valve
• 25. Steering cylinder(s)
• 26. High pressure relief valve (180 bar)
• 27. Load sensing valve
• 27a. Pilot line
• 28. Lateral flotation control valve
• 29. Lateral flotation cylinder
• 30. Lateral float minimum pressure valve (60 bar)
• 30a. Lateral float accumulator (120 bar)
• 30b. Lateral float accumulator (85 bar)
• 31. Drain hose
• 32. Low pressure filter
• 33. Breather with filter and non-return valve
• 34. Top plate
• 35. Accumulator (0.7 - 1.3 bar)
• 36. High pressure relief valve (210 bar)
• P: Inlet (high pressure)
• R: Return (low pressure)
• - - -: Pilot line, load sensing line
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ZEIL04CS0006H0B 1
Adjustable Steering Axle
Fixed straw elevator
Hydraulic reverser
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ZEIL04CS0007H0B 2
Fixed or Powered Rear Axle
Lateral flotation
Hydraulic reverser
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ZEIL04CS0008H0B 3
Adjustable Steering Axle
Fixed straw elevator
Electrical reverser system
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PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic symbol (A.10.A

- C.20.C.20)
CS540, CS640, CS520, CS660
Engine Reservoir
Hydraulic pump, direction Hydraulic pump

with variable displacement single direction fixed
displacement
Hydraulic pump, Steering motor

directional with (bi-directional)
displacement
Motor, single direction Motor bi-directional fixed

fixed displacement displacement
2 position valve 3 position valve
Proportional (PWM) valve Pressure relief valve
Solenoid controlled Proportional solenoid

movement movement (Pulse Width
Modulation)
Movement by or against Movement by or against

spring tension adjustable spring tension
Movement by or against Lock-out valve

oil pressure
Non return valve Non return valve, pressure

controlled
Quick coupler with non Flexible hose

return valve
Restrictor Thermostat
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Hydro-pneumatic Cylinder
accumulator
Filter Filter opening
Shuttle valve Temperature sender
Pressure sensor
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PRIMARY HYDRAULIC POWER SYSTEM - Overview (A.10.A -

C.40.B.10)
CS540, CS640, CS520, CS660
ZEIL04CS0085G0B 1
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ZEIL04CS0086G0B 2
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PRIMARY HYDRAULIC POWER SYSTEM - Component localisation

(A.10.A - C.40.B.20)
CS540, CS640, CS520, CS660
NOTE: To find the location of those components, refer to PRIMARY HYDRAULIC POWER SYSTEM - Overview
(A.10.A - C.40.B.10)
Header lift cylinders (9)
ZDA5998C 1
Lateral float cylinder (29) (If lateral float installed)
ZDA7537A 2
Header quick-release coupler (18) (or screw

couplers)
ZDA6003C 3
(If hydraulic reverser)

Screw couplers with non return valve (22)
Header and straw elevator reversing motor (23)
ZDA6258B 4
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Steering valve (24)
ZDA7538A 5
Unload tube cylinder (14)
ZDA7539A 6
Oil reservoir (5)

Filler cap with filter (6)
Breather with filter and non-return valve (33)
Low pressure filter (32)
ZDA7346F 7
Steering cylinder(s) (25)
ZDA7540A 8
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Load sensing valve (27)

Lateral flotation control valve (28)
Lateral float minimum pressure valve (60 bar) (30)
Lateral float accumulator (120 bar) (30a)
Lateral float accumulator (85 bar) (30b)
ZDA6268B 9
Load sensing valve (7)

Unloading tube control valve (13)
Reel vertical adjustment valve (15)
Reel horizontal adjustment valve (17)
Header and straw elevator reversing motor (21)
Accumulator (35)
ZEIL04CS0089A0B 10
Header height control valve (8)

High pressure relief valve (36)
ZEIL04CS0084A0B 11
Accumulator control valve (10)

Header suspension accumulator (11)
Pressure sensor (12)
ZDA7561A 12
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Main hydraulic pump (2)

Pump (3) (Steering circuit)
Pump (4) (Lateral flotation)
High pressure relief valve (26)
ZDA7560A 13
Drain hose (31)
ZDA5943E 14
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Relief valve - Static description (A.10.A.16 - C.30.A.20)

CS540, CS640, CS520, CS660
The high pressure relief valve is situated above the hydraulic triple pump.
• The high pressure relief valve (26), set at 180 bar (2611 psi), protects the header height and main control
hydraulics.
• A relief valve incorporated in the main control valves has no function in our hydraulic system. Therefore, this
relief valve is set at 175 bar (2538 psi) to avoid interference.
ZDA7560B 1
ZDF0543A 2
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Stack valve - Dynamic description (A.10.A.18 - C.30.A.10)

CS540, CS640, CS520, CS660
If all valves are in the "0" position, then:

The valves (13), (15), (17), (21) and (28), (Refer to Stack valve - Static description (A.10.A.18 - C.30.A.20)) are
closed, which means that the oil can not flow through these valves.
The pressure raises at (7b), (27b), until the load sensing spool is pushed open against spring pressure (delta P=3
bar) and the return pressure in the pilot line (7a), (27a). Now pump oil flows into the return line at standby pressure.
When activating one or more of the control spools, the hydraulic cylinder pressure (pump pressure measured after
the spool restriction) is present in the pilot line (7a), (27a) and closes the load sensing spool. The pressure oil is
available for the activated control spool(s).
When the pump pressure reaches the cylinder pressure (+3 bar), the load sensing spool is pushed partially open.
The necessary amount of oil will flow to the control spool at the needed pressure. Excess oil is dumped into the
return line.
ZDA6268B_55 1
When the cylinder reaches end of stroke, the system pressure starts to raise. When the pilot pressure reaches 207
bar for the main stack valve (175 bar for the lateral float stack valve) the pressure relief valve is pushed open and
system pressure is limited to 210 bar (207 + 3 bar)The load sensing lockout valves, (13a), (15a), (17a), (21a), (28a)
between the different control spools make sure that pilot pressure cannot escape into the return over not used control
spools. When using more then one control spool the highest pilot pressure will operate the load sensing spool.
ZEIL04CS0089A0B 2
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ZEIL04CS0097F0B 3
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The load sensing lockout valves, (13a), (15a), (17a), (21a), (28a) between the different control spools make sure
that pilot pressure can not escape into the return over not used control spools. When using more then one control
spool the highest pilot pressure will operate the load sensing spool.
ZEIL04CS0098A0B 4
Function of lockout valves in the connections towards the cylinders.
When standby oil enters area (2a), ball (5) and valve (6) will be moved against the pressure in area (1a) and
spring tension (7).
Now standby oil is allowed to enter area (1a) through housing (4) towards the hydraulic cylinder (1).
The other side of the cylinder is connected to the lockout valve on the other side of connecting piece (2). This
lockout valve is still closed, so pressure will build up until connecting piece (2) moves to the right and opens the
right-hand side lockout valve, allowing the oil to enter the return line.
For some applications, the valve housing (4) is completely blocked by shims (1). This is to make sure that the
passage between area (1a) and (2a) is blocked. In that case the full oil flow will have to pass through valve housing
(4) instead of moving the complete valve housing.
ZDF0489A 5
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Operation of reversing system valve (21).

In neutral position of the valve, both motor connections are connected to each other by the returns system. The
load sensing line is also connected to the return system. When switching the valve to position “1" or “2", lockout
valve (21a) (Refer to Stack valve - Static description (A.10.A.18 - C.30.A.20)) allows standby oil to flow into the
load sensing line. Now full oil flow is available towards the hydraulic motor.
ZEIL04CS0089A0B 6
Load sensing lockout valve (21a)
ZEIL04CS0098A0B 7
ZDF0488A 8
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Operation of the reel vertical adjustment valve (15).

When switching one of these valves, load sensing lockout valve (15a) (Refer to Stack valve - Static description
(A.10.A.18 - C.30.A.20)) allows standby oil to enter the load sensing line. Now full oil flow is available towards the
hydraulic cylinder.These valves are connected to a single-acting cylinder which means that only one lockout valve
(fig.5) is provided in the connection towards the cylinder.
ZEIL04CS0089A0B 9
Load sensing lockout valve (15a)
ZEIL04CS0098A0B 10
ZEIL04CS0099F0B 11
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Operation of the unloading tube control valve (13), the reel horizontal adjustment valve (17) and the lateral float
control valve (28).
When switching one of these valves, lockout valves (13a), (17a) or (28a) allow standby oil to enter the load
sensing line.
Now full oil flow is available towards the hydraulic cylinder. Lockout valves are installed in the connections towards
the cylinder. (see fig.5)
ZEIL04CS0089A0B 12
ZDA6268B_55 13
ZDF0485A 14
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Stack valve - Static description (A.10.A.18 - C.30.A.20)

CS540, CS640, CS520, CS660
The main hydraulic system will be a open centre load sensing system that controls all high pressure functions: All
header functions and unloading auger swing.
The hydraulic system on CS combines contains two stack valves:
• Main stack valve (1). (see also hydraulic schematic below) Located at the left-hand side of the cab behind
the steering platform.
ZEIL04CS0089A0B 1
• Lateral float stack valve (2). (see also hydraulic schematic below) Located at the left-hand side of the straw
elevator.
ZDA6268B_55 2
• Header height control valve (3). (see also hydraulic schematic below) Located at the engine compartment.
ZEIL04CS0084A0B 3
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ZEIL04CS0007H0C 4
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The stack valves (1) and (2) consists of two main parts.
• Control valves for oil supply and load sensing (7 and 27)
Refer to PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (A.10.A - C.20.B.20)
Load sensing is a system which avoids high pressure when the valves are in neutral position and consequently,
less heating up of the oil and creating load-independent flow rate control.
ZDA6268B_55 5
• Control valves with load sensing (13-15-17-21-28)

Refer to PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (A.10.A - C.20.B.20)
ZEIL04CS0089A0B 6
13 Unloading tube movement

15 Reel vertical adjustment
17 Reel horizontal adjustment
21 Reversing system
28 Lateral float system
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Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDF0842A 1
Main hydraulic pump
1 Pump housing 2 Bearing end plate

3 Radial-lip-type oil seal 4 Retaining ring
5 Housing cover 6 Toothed washer
7 Toothed gear 8 Toothed gear
9 Woodruff key 10 Hexagon nut
11 Spring lock washer 12 Protective cap
13 Protective cap 14 Bushing
15 Bushing 16 Head screw
17 Straight pin 18 Straight pin
19 Set of seals
NOTE: Tighten the screw (16) with a torque between 12 - 16 Nm. (9 - 12 lb ft)
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Oil filter - Static description (A.10.A.24 - C.30.A.20)

CS540, CS640, CS520, CS660
The low pressure filter (32) is installed on top of the hydraulic reservoir (5) and has a bypass (non-return) valve
set to 1.15 bar (17 psi).The return oil from the hydraulics system is flowing through the low pressure filter before
entering the hydraulic oil reservoir.
ZDA7346F_58 1
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Breather - Static description (A.10.A.26 - C.30.A.20)

CS540, CS640, CS520, CS660
The breather (33) allows the air in the reservoir to escape whenever a considerable oil flow arrives at the reservoir
(e.g. when lowering the attachment).
ZDA7346F_58 1
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Stack valve - Remove (A.10.A.18 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Start the engine.

2. Ensure that the machine component involved (e.g.
reel, header, ...) is completely down (cylinder fully
retracted) to release any possible pressure on the
valves.
3. Stop the engine.
IMPORTANT: Be sure that the area around the stack
valves is clean before removing them. Dirt contamination
will cause hydraulic component damage and/or failure.
Use caution while washing to keep electrical components
as dry as possible.
4. Drain the hydraulic oil from the reservoir trough the
drain hose and catch the oil into a clean suitable
container. (Refer to the CS Operator’s Manual:
"Section 4 - Lubrication and Maintenance")
5. Disconnect all the electrical connectors (1) from the
valve solenoids.
NOTE: Mark all electrical connector locations for proper
connection during assembly.
ZDA7884A 1
6. Loosen and disconnect the hydraulic line fittings (2)

from the stack valve. Cap and plug all lines and
fittings.
NOTE: When disconnecting the hydraulic lines, have a
suitable container readily available to capture any residual
hydraulic oil.
IMPORTANT: Lines and fittings must be capped and
plugged when disconnected to avoid contamination. Dirt
contamination will cause hydraulic component damage
and/or failure.
ZDF0480A 2
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7. Loosen the two bolts (3) at the bottom of the support

of the stack valve.
ZDF0738A 3
8. Loosen the two bolts (4) at the top of the support

of the stack valve.
Now is it possible to remove the stack valve with
the support.
ZDF0737A 4
9. Loosen the bolts to remove the support (5) from the

main stack valve.
ZEIL04CS0090A0B 5
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Stack valve - Install (A.10.A.18 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the stack valve with the support (5) installed

in place.
ZEIL04CS0090A0B 1
2. Install the two bolts (4) at the top of the support.
ZDF0737A_61 2
3. Install the two bolts (3) at the bottom of the support.
ZDF0738A 3
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4. Connect all hydraulic line fittings (2) with the stack

valve.
ZDF0480A_62 4
5. Connect the electrical wires (1) to the valve

solenoids.
ZDA7884A 5
6. Reinstall the plug of the drain hose.

Fill the hydraulic reservoir with proper type and
amount of hydraulic fluid.
(Refer to the CS operator’s manual: "Lubrication
and Maintenance")
Start the engine and check all connections for leaks.
Check the hydraulic oil level.
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Stack valve - Repair (A.10.A.18 - F.75.C.32)

CS540, CS640, CS520, CS660
If a control valve does not respond to a switch command, either an electric or a hydraulic problem may be the cause.
1. ° HYDRAULIC CAUSE:
In case of a valve failure, the individual valve has
to be replaced. Repair of the valve is not possible.
Only replacements of seal rings is possible.
2. In case of oil leakage between the valve order a
seal kit which must be installed between the valves.
A different O-ring kit is available to service the load
sensing valve (7).
ZEIL04CS0097F0B 1
3. In case of an internal leakage (when cylinders are

moving due to the own weight), order the repair kit.
4. In case of an external leakage of the lockout valve,
order:
Shim repair kit, O-ring.
IMPORTANT: When installing one of the above mentioned
repair kits, the following procedure must be used to avoid
external leakages:
valves.
6. Loosen one (or two) hydraulic tubes at the
concerned valve to release any remaining pressure
so as to avoid loss of components on removal.
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7. Install the complete lock out valve, except for the

shims (1), O-ring (9), spring (7) and the plug (8).
8. Push the valve (6) and the valve housing (4) as
deep as possible.
9. Measure depth "X" with a sliding gauge.
10. Measure depth "Y" of the thread.
11. Fill-up the gap between the valve housing (4) and
the plug with two copper washers + metal washers
included in the kit so that: Thickness of washers
(2x copper + metal) = (X-Y) + 0.2 - 0.4 mm
Copper washers have to be compressed on
installation of plug (8).
12. Install spring the (7), O-ring (9) and the plug (8).
ZDF0489B 2
1 Shims 2 Connecting piece

3 Pin 4 Valve housing
5 Ball 6 Valve
7 Spring 8 Plug
9 O-ring
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13. Before installing the stack valve, place all the valves
on a horizontal, level surface and pay attention to
the sequence and the tightening of the torques.
NOTE: Tighten the nuts (1), (2) and (3) in that order.
NOTE: Use always the same torques (see below), also
if the stack valve is equipped without header and straw
elevator reversing valve.
ZEIL04CS0091G0B 3
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Nut (1) and (2): torque 25 - 33 Nm (18.4 - 24.3 lb ft) Nut (3): torque 13.5 - 18 Nm (10 - 13 lb ft)
Allen screw (4): torque 67 - 89 Nm (49.4 - 65.64 lb ft) Allen screw (5): torque 54 - 72 Nm (39.8 - 53.1 lb ft)
Allen screw (6): torque 2.6 - 3.1 Nm (1.9 - 2.28 lb ft) Allen screw (7): torque 38 - 51 Nm (28 - 37.6 lb ft)
14. ° ELECTRIC CAUSE:
The solenoid does not operate the valve spool.
No power supply to the solenoid spool or failure of
the solenoid spool.
In this case, the valve spool can be manually
activated by pushing on the rubber cap of the
solenoid and moving the valve spool into the an
operating position.
As a provisional solution, if there is no power
available on a solenoid, the electric wires of another
valve (which is not used needed at the moment)
may be connected to that solenoid.
DANGER
Z006 - Before activating a solenoid manually, ensure
that everybody stands clear of the machine. Activate
it just long enough to notice that the valve works.
CAUTION
Z019 - Never put 12V continuously to a solenoid as
this will cause the solenoid to burn. It is allowed to
put 12V on a solenoid as a pulse or maximum 7V
continuously!
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Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Remove the hydraulic triple pump, refer to

Hydraulic pump - Remove (A.10.A.20 - F.10.A.10).
NOTE: Tighten the screw (4) with a torque between 22 -
28 Nm. (16 - 21 lb ft) Tighten the screw (5) with a torque
between 47 - 55 Nm. (35 - 40.5 lb ft)
ZDF0560A 1
ZDF0843A 2
Hydraulic triple pump
1 Main hydraulic pump 2 Hydraulic pump (steering circuit)

3 Hydraulic pump (lateral float)
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Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)

CS540, CS640, CS520, CS660
CAUTION
Z009 - Before starting a service job, always:-Shut off the engine-Remove the ignition key-Switch off the
battery switch-Wait until all parts have completely stopped rotating
IMPORTANT: Be sure that the area around the hydraulic triple pump is clean before remove them. Dirt
contamination will cause hydraulic component damage and/or failure.
1. Drain the hydraulic oil from the reservoir trough the
drain hose into a clean suitable container. (Refer to
your CS operator’s manual "Section 4 - Lubrication
and Maintenance")
2. Loosen the locknut nut (2) and remove the hydraulic
pump drive belt.
ZDF0479A 1
3. Loosen the hose clamp (5) to remove the hose and

the hydraulic line fitting (6). (Lateral flotation)
Loosen the hose clamp (4) to remove the hose and
the hydraulic line fitting (7). (Steering circuit)
NOTE: Mark the hose locations for proper connection
during installation.
NOTE: When disconnecting the hydraulic lines, have a
hydraulic oil.
ZDA7560B_67 2
4. Loosen the hose clamp (3) to remove the hose and

the hydraulic line fitting (8) from the main hydraulic
pump.
IMPORTANT: Lines and fittings must be capped and
plugged when disconnected to avoid contamination. Dirt
contamination will cause hydraulic component damage
and/or failure.
ZDF0549A 3
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A.10.A / 44
5. Remove the nut (1) and the washers.

Remove the pulley (2).
ZDF0436A 4
6. Loosen the four nuts (3) and remove the hydraulic

triple pump.
ZDF0437A 5
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Hydraulic pump - Install (A.10.A.20 - F.10.A.15)

CS540, CS640, CS520, CS660
CAUTION
1. Bring the hydraulic triple pump in place and install

the four bolts.
Install the washers and tighten with the four nuts (3).
ZDF0437A_68 1
2. Install the hose and tighten with the hose clamp (3)
and connect the hydraulic line fitting (8) of the main
hydraulic pump.
Install the hose and tighten with the hose clamp (4)
and connect the hydraulic line fitting (7). (Steering
circuit)
Install the hose and tighten with the hose clamp (5)
and connect the hydraulic line fitting (6). (Lateral
flotation)
ZDA7560B_69 2
3. Tighten the fittings securely.
ZDF0549A_70 3
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4. Install the pulley (2).

Install the washer and tighten with the nut (1).
ZDF0436A_71 4
5. Install the drive belt.

Adjust the hydraulic drive belt by adjusting
the locknut (2). Refer to the CS Operator’s
manual: “SECTION 4 - LUBRICATION AND
MAINTENANCE“: paragraph headed: “Belts and
Chains".
ZDF0479A 5

Fill the hydraulic reservoir with proper type and
amount of hydraulic fluid. (Refer to the CS
Operator’s manual: “SECTION 4 - LUBRICATION
AND MAINTENANCE")
Start the engine and check all connections for leaks.
Check the hydraulic oil.
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A.10.A / 47
Index
Breather - Static description (A.10.A.26 - C.30.A.20) 34

CS540, CS640, CS520, CS660
Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25) 43
CS540, CS640, CS520, CS660
Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20) 32
CS540, CS640, CS520, CS660
Hydraulic pump - General specification (A.10.A.20 - D.40.A.10) 6
CS540, CS640, CS520, CS660
Hydraulic pump - Install (A.10.A.20 - F.10.A.15) 46
CS540, CS640, CS520, CS660
Hydraulic pump - Remove (A.10.A.20 - F.10.A.10) 44
CS540, CS640, CS520, CS660
Oil filter - Static description (A.10.A.24 - C.30.A.20) 33
CS540, CS640, CS520, CS660
PRIMARY HYDRAULIC POWER SYSTEM - Component localisation (A.10.A - C.40.B.20) 18
CS540, CS640, CS520, CS660
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (A.10.A - C.20.B.20) 7
CS540, CS640, CS520, CS660
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic symbol (A.10.A - C.20.C.20) 13
CS540, CS640, CS520, CS660
PRIMARY HYDRAULIC POWER SYSTEM - Overview (A.10.A - C.40.B.10) 15
CS540, CS640, CS520, CS660
PRIMARY HYDRAULIC POWER SYSTEM - Torque (A.10.A - D.20.A.10) 4
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Stack valve - Dynamic description (A.10.A.18 - C.30.A.10) 23
CS540, CS640, CS520, CS660
Stack valve - Install (A.10.A.18 - F.10.A.15) 37
CS540, CS640, CS520, CS660
Stack valve - Remove (A.10.A.18 - F.10.A.10) 35
CS540, CS640, CS520, CS660
Stack valve - Repair (A.10.A.18 - F.75.C.32) 39
CS540, CS640, CS520, CS660
Stack valve - Static description (A.10.A.18 - C.30.A.20) 29
CS540, CS640, CS520, CS660
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PNEUMATIC SYSTEM - 20.A
CS540
CS640
CS520
CS660
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Contents
TECHNICAL DATA
Air compressor
Air compressor - Torque (A.20.A.31 - D.20.A.10) 4
CS540, CS640, CS520, CS660
Air compressor - Special tools (A.20.A.31 - D.20.A.40) 4
CS540, CS640, CS520, CS660
Air compressor - General specification (A.20.A.31 - D.40.A.10) 4
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
PNEUMATIC SYSTEM - Pneumatic schema (A.20.A - C.20.B.30) 5

CS540, CS640, CS520, CS660
PNEUMATIC SYSTEM - Static description (A.20.A - C.30.A.20) 9
CS540, CS640, CS520, CS660
PNEUMATIC SYSTEM - Component localisation (A.20.A - C.40.B.20) 10
CS540, CS640, CS520, CS660
PNEUMATIC SYSTEM - Overview (A.20.A - C.10.A.10) 12
CS540, CS640, CS520, CS660
Command valve
Command valve - Static description (A.20.A.12 - C.30.A.20) 15
CS540, CS640, CS520, CS660
Relief valve
CS540, CS640, CS520, CS660
Air compressor
Air compressor - Static description (A.20.A.31 - C.30.A.20) 17
CS540, CS640, CS520, CS660
Sensing system
Sensing system Pressure switch - Static description (A.20.A.95.81 - C.30.A.20) 18
CS540, CS640, CS520, CS660
SERVICE
Command valve
Command valve - Remove (A.20.A.12 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Command valve - Install (A.20.A.12 - F.10.A.15) 21
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
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A.20.A / 2
Command valve - Disassemble (A.20.A.12 - F.10.A.25) 25
CS540, CS640, CS520, CS660
Command valve - Assemble (A.20.A.12 - F.10.A.20) 26
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Relief valve
Relief valve - Remove (A.20.A.16 - F.10.A.10) 29
CS540, CS640, CS520, CS660
Relief valve - Install (A.20.A.16 - F.10.A.15) 30
CS540, CS640, CS520, CS660
Air tank
Air tank - Remove (A.20.A.22 - F.10.A.10) 31
CS540, CS640, CS520, CS660
Air tank - Install (A.20.A.22 - F.10.A.15) 32
CS540, CS640, CS520, CS660
Air compressor
Air compressor - Remove (A.20.A.31 - F.10.A.10) 33
CS540, CS640, CS520, CS660
Air compressor - Disassemble (A.20.A.31 - F.10.A.25) 35
CS540, CS640, CS520, CS660
Air compressor - Overhaul (A.20.A.31 - F.10.A.40) 41
CS540, CS640, CS520, CS660
Air compressor - Assemble (A.20.A.31 - F.10.A.20) 42
CS540, CS640, CS520, CS660
Air compressor - Install (A.20.A.31 - F.10.A.15) 48
CS540, CS640, CS520, CS660
DIAGNOSTIC
Air compressor
Air compressor - Troubleshooting (A.20.A.31 - G.40.A.10) 50
CS540, CS640, CS520, CS660
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A.20.A / 3
DISTRIBUTION SYSTEMS - PNEUMATIC SYSTEM
Air compressor - Torque (A.20.A.31 - D.20.A.10)

CS540, CS640, CS520, CS660
Connecting rod bolts 6 Nm (53 lb ft.)

Cylinder head bolts 20 Nm (14.8 lb ft.)
Drive pulley retaining nut 100 Nm (73.8 lb ft.)
Air compressor - Special tools (A.20.A.31 - D.20.A.40)

CS540, CS640, CS520, CS660
Description Tool No.

Piston ring compressor 291048
(Standard band type ring compressor 60-125 mm)
Air compressor - General specification (A.20.A.31 - D.40.A.10)

CS540, CS640, CS520, CS660
Type Single piston

Bore 75 mm (2.95 in.)
Stroke 36 mm (1.42 in.)
Swept volume 159 cm3
Maximum permissible pressure temperature in service 220 ° C (428 ° F)
Crankshaft end play 0.2-0.6 mm (0.079-0.236 in.)
Maximum air tank pressure 10 bar (145 psi)
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PNEUMATIC SYSTEM - Pneumatic schema (A.20.A - C.20.B.30)

CS540, CS640, CS520, CS660
1. Engine
2. Air compressor
3. Turbo
4. Air filter
5. Pressure relief valve (8 bar)
6. Air reservoir
7. Cock
8. Union
9. Restriction (unloading engagement)
10. Filter
11. Pressure switch
12. Threshing engaging valve
13. Restriction (threshing engagement)
14. Restriction (header engagement)
15. Threshing clutch
16. Straw elevator engaging valve
17. Straw elevator engaging valve cylinder
18. Unloading engaging valve
19. Unloading engaging cylinder
20. Rotary union
21. Front plate
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ZDA7845A 1
Pneumatic schematic (From series 1320 to 1368)
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A.20.A / 6
ZEIL04CS0005H0B 2
Pneumatic schematic (From series 1376)
12118 1 02/07/2004
A.20.A / 7
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A.20.A / 8
PNEUMATIC SYSTEM - Static description (A.20.A - C.30.A.20)

CS540, CS640, CS520, CS660
Engaging of the threshing mechanism is done by a pneumatic clutch. Engaging of the straw elevator and the
unloading system is done by use of pneumatic cylinders.
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A.20.A / 9
PNEUMATIC SYSTEM - Component localisation (A.20.A - C.40.B.20)

CS540, CS640, CS520, CS660
NOTE: To find the location of those components, refer to PNEUMATIC SYSTEM - Overview (A.20.A - C.10.A.10)
Air compressor (2)
ZDA6252B 1
Pressure relief valve (5)
ZDA7589B 2
Air reservoir (6)

Cock (7)
Union (8)
Filter (10)
ZEIL04CS0088A0B 3
Threshing engaging clutch (15)

Rotary union (20)
ZDA7084D 4
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From series 1320 to 1368:

Unloading tube engagement valve (18)
Straw elevator engagement valve (16)
Pressure switch (11)
Threshing engaging valve (12)
Restriction (13)
ZDA 6611E 5
From series 1376:

Unloading tube engagement valve (18)
Straw elevator engagement valve (16)
Threshing engagement valve (12)
Restriction (13)
Front plate (21)
ZEIL04CS0055A0E 6
Header engaging cylinder (17)

Restriction (14)
ZDA7483B 7
Unloading engaging cylinder (19)

Restriction (9)
ZDA7878A 8
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PNEUMATIC SYSTEM - Overview (A.20.A - C.10.A.10)

CS540, CS640, CS520, CS660
ZEIL04CS0083G0B 1
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A.20.A / 12
ZEIL04CS0082G0B 2
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A.20.A / 13
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A.20.A / 14
Command valve - Static description (A.20.A.12 - C.30.A.20)

CS540, CS640, CS520, CS660

These valves are provided with a manual engaging control. This control (small yellow lever (1) located on the valve
body) must be engaged in the event of any electrical failure or to test the pneumatic systems controlled by them. To
engage, turn the control 1/4 turn clockwise. To disengage the control, turn it counter clockwise.
CAUTION
Z014 - For safety raisons, make sure nobody is near the combine when engaging or disengaging the
valve(s), even when the engine is not running!
ZDF0811A 1
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A.20.A / 15
Relief valve - Static description (A.20.A.16 - C.30.A.20)

CS540, CS640, CS520, CS660
The pressure relief valve is developed to protect the system against pressures higher than 8 bar (116 psi).Port
(1) is connected to the air compressor, port (2) is connected to the pressurized reservoir.When the pressure on
port (2) reaches 8 bar (116 psi), the control valve (9d) will be activate which means that also control valve (9c)
will be activated. The pressure from the compressor will now pass through port (5).If the pressure drops below 8
bar (116 psi) by activation a engaging valve, control valve (9d) will close.Valve (9c) will not close immediately but
will remain in the open position until the pressure exerted on the control of valve (9c) will be reduced by 0.6 bar
(8.7 psi). Then the air will pass through valve (9b).
1. Inlet
2. Outlet
3. Auxiliary supply
4. Tyre inflation device
5. Exhaust for compressor idling
ZDA7671A 1
Schematic diagram
ZDA7672A 2
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A.20.A / 16
Air compressor - Static description (A.20.A.31 - C.30.A.20)

CS540, CS640, CS520, CS660
The air compressor (1) is a single cylinder, belt driven air compressor, which supplies air to a reservoir tank,
enabling the operator to have a source of compressed air for engaging the header and straw elevator, threshing and
unloading system and also for cleaning purposes and tyre inflation. The compressor is mounted on the modular
engine frame.Engine oil is supplied through a line connected directly to the engine, using engine oil pressure to
lubricate the compressor. The compressed air is delivered through tubing to a combination pressure relief control
valve, and from there to the reservoir tank located on the right-hand side of the combine. A quick disconnect fitting
allow easy connection to the air supply for blow off nozzles as well as tyre inflation equipment.
ZDA6252B_86 1
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A.20.A / 17
Sensing system Pressure switch - Static description (A.20.A.95.81 -

C.30.A.20)
CS540, CS640, CS520, CS660
This switch (11) has the function of ensuring the proper engagement of the threshing mechanism, i.e. air flow is
released only after 6 bar (87 psi) air pressure is built up in the reservoir.This means that engaging of the threshing
mechanism is not possible if the air pressure is too low. (red led is showing on the monitor)
As soon the pressure increases above about 6 bar (87 psi), the switch (11) toggle. (red and green led is glowing
on the monitor) This is a sign for the operator to reactivate the threshing engagement switch.After reengaging
the threshing mechanism, the green led is glowing.
ZDA6611F 1
From series 1376:
ZEIL04CS0055A0D 2
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A.20.A / 18
Command valve - Remove (A.20.A.12 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Bleed the air from the system by opening the drain

(2) at the bottom of the air reservoir (1).
ZDA6374B 1
2. Loosen the screw and remove the electrical

connector(s) (3), using a screw driver.
ZDF0757A 2
3. Disconnect the air hose(s) from the valve(s). Push

onto the ring (4) after pull the air hose (5) out of
the valve.
NOTE: Mark all air hose locations for proper connection
during assembly.
ZDF0758A 3
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A.20.A / 19
4. Push down the yellow lever (6) to disconnect the

valve (7) from the connection support (8).
ZDF0759A 4
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A.20.A / 20
Command valve - Install (A.20.A.12 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Push down the yellow lever (6) and bring the valve
(7) in place to the connection support (8).
Release the yellow lever (6).
ZDF0760A 1
2. Connect the air hose(s) (5) onto the valve(s).
ZDF0758B 2
3. Install the electrical connector (3) onto the valve and

tighten with the screw.
ZDF0757A_77 3
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A.20.A / 21
4. Close the drain (2) at the bottom of the air reservoir

(1).
ZDA6374B 4
5. Start the engine and check for air leaks.
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A.20.A / 22
Command valve - Remove (A.20.A.12 - F.10.A.10)

CS540, CS640, CS520, CS660
From series 1376:

(2) located at the bottom of the air reservoir (1).
ZDA6374B 1
2. Loosen the screws (3), to remove the connector(s)

(4).
Disconnect the connector (5).
ZEIL04CS0022A0B 2
3. Remove the connector (6) by using a screw driver

and pushing down the connector.
ZEIL04CS0023A0B 3
4. Disconnect the air hoses (8) from the valves. Push

onto the ring (7) after pull the air hose (8) out of
the valve.
NOTE: Mark all air hose locations for proper connection
during assembly.
ZEIL04CS0024A0B 4
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A.20.A / 23
5. On both sides, loosen the four screws (9) of the

valve block, using a screw driver.
ZEIL04CS0025A0B 5
6. Move the assembled valve block (10) to the right.
ZEIL04CS0026A0B 6
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A.20.A / 24
Command valve - Disassemble (A.20.A.12 - F.10.A.25)

CS540, CS640, CS520, CS660
From series 1376:
Prior operation: Remove the valve block, refer to Command valve - Remove (A.20.A.12 - F.10.A.10).
1. Loosen the two screws (1).
ZEIL04CS0027A0B 1
2. Now is it possible the disassemble the valve block.

Threshing engaging valve (12)
Straw elevator engaging valve (16)
Unloading engaging valve (18)
Front plate (21)
ZEIL04CS0028A0B 2
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Command valve - Assemble (A.20.A.12 - F.10.A.20)

CS540, CS640, CS520, CS660
From series 1376:
1. Install the valves in these sequence onto the front

plate (21).
Valves (18), (16), (12), and pressure switch (11).
ZEIL04CS0028A0B 1
2. Install and tighten the two screws (1) by hand.
ZEIL04CS0027A0B 2
Next operation: Refer to Command valve - Install (A.20.A.12 - F.10.A.15).
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A.20.A / 26
Command valve - Install (A.20.A.12 - F.10.A.15)

CS540, CS640, CS520, CS660
From series 1376:
1. Slide the pre-assembled valve block (10) onto his

place.
ZEIL04CS0026A0B 1
2. On both sides, tighten the four screws (9), using

a screw driver.
ZEIL04CS0025A0B 2
3. Connect the air hoses onto the valves.
ZEIL04CS0024A0B 3
4. Install the connector (6) onto his support.
ZEIL04CS0023A0B 4
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A.20.A / 27
5. Connect the connector (5).

Install the connectors (4) onto the right valves and
tighten the screws (3).
NOTE: Do not to forget to install the seals between the
connector and the valves.
ZEIL04CS0022A0B 5

(1).
ZDA6374B 6
7. Start the engine and check for leaks.
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Relief valve - Remove (A.20.A.16 - F.10.A.10)

CS540, CS640, CS520, CS660

ZDA6374B 1
2. Loosen and disconnect the air line fittings (1) from

the pressure relief valve (2).
Remove the air line tubes (3).
Loosen and remove the mounting bolts (4) and nuts
from the pressure relief valve and bracket.
Remove the pressure relief valve (2).
ZDA7589A 2
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Relief valve - Install (A.20.A.16 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Position the pressure relief valve (2) on the

mounting bracket and install the two mounting bolts
(4). Secure with the lock washers and nuts.
Connect and tighten the air line tube fittings (1)
securely.
ZDA7589A 1

(1).
ZDA6374B 2
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Air tank - Remove (A.20.A.22 - F.10.A.10)

CS540, CS640, CS520, CS660

ZDA6374B_84 1
2. Loosen the air line tube fittings (3) and (4).

Disconnect the air line tubes from the air tank
reservoir (2).
ZDA7590A 2
3. Loosen the two bolts (5) from the air tank reservoir
mounting straps (6).
Remove the air tank reservoir (2) from the mount.
ZDA7591A 3
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Air tank - Install (A.20.A.22 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Position the air reservoir (2) in the mounting straps

(6).
Tighten the mounting bolts (5), hand tight.
ZDA7591A_85 1
2. Connect the air line tube fittings (3) and (4) to the air
reservoir (2).
Tighten the air line tube fittings (3) and (4) securely.
Tighten the mounting bolts (5).(see fig.1)
ZDA7590A 2

(1).
ZDA6374B 3
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Air compressor - Remove (A.20.A.31 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Open the rotary dust screen door with the key (1).
ZDA7387A 1
2. Loosen the bolts and remove the shielding (1).
ZDA7586A 2
3. Loosen the fittings (1) and disconnect the hoses (2)

from the air compressor (3).
Loosen the hose clamp (4) and disconnect the hose
(5) from the air compressor (3).
ZDA7587A 3
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4. Loosen and remove the three air compressor

mounting nuts (1) and turn the tension adjustment
bolt (2) counter-clockwise to loosen tension on the
air compressor drive belt (3).
ZDA7588A 4
5. Remove the drive belt (3).

Remove the tension adjustment bolt (2), and lift the
compressor from the mount plate.
ZDA7713A 5
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Air compressor - Disassemble (A.20.A.31 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Remove the nut (1) and the washer (2) securing the
pulley (3) to the compressor drive shaft.
20013211 1
2. Remove the pulley (1) from the tapered shaft (2).
20013212 2
3. Loosen and remove the four nuts (1) washers

and socket head cap screws (2) securing the
compressor to the mount plate (3).
20014972 3
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4. Loosen and remove the four cylinder head bolts (1).
20013213 4
5. Carefully remove the cylinder head (1) from the

compressor (2).
20013214 5
6. Loosen and remove the two bolts (1) and the

spacers (2).
20013215 6
7. Remove the plate (1) the valve plate (2) and the
washer (3) from the manifold plate (4).
20013216 7
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8. Remove the manifold plate (1) from the compressor

(2).
Remove and discard the cylinder head gasket (3).
20013217 8
9. Remove the reed valve (1) from the compressor (2).

Remove and discard the manifold plate gasket, (3).
20013218 9
10. Loosen and remove the four end cap screws (1). If
necessary, use an impact driver (2).
20013219 10
11. Remove the end cap (1) from the compressor.

Remove and discard the crankshaft seal (2) and the
O-ring (3) from the end cap.
20013222 11
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12. Loosen and remove the four bolts (1) from the end
cover (2).
Remove the end cover (2) from the compressor.
20013220 12
13. Turn the compressor over and remove the two frost
plugs (1) from the bottom of the compressor to gain
access to the connecting rod bolts.
20013221 13
14. Insert a Torx bit through the frost plug holes. Loosen
and remove the connecting rod bolts.
20013223 14
15. Remove the piston and connecting rod assembly

(1) from the cylinder.
20013224 15
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16. Remove the crankshaft (1) from the compressor.
20013225 16
17. Remove the connecting rod cap (1) from the

compressor.
20013226 17
18. Remove the wrist pin retaining ring (1) on each side
of the piston (2).
20013227 18
19. Remove the wrist pin (1) from the piston (2).
IMPORTANT: Note the orientation of the piston to the
connecting rod by observing the stamping on the crown of
the piston in relation to the connecting rod.
20014964 19
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A.20.A / 39
20. Separate the connecting rod (1) from the piston (2).
20014965 20
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A.20.A / 40
Air compressor - Overhaul (A.20.A.31 - F.10.A.40)

CS540, CS640, CS520, CS660
1. Clean all parts in a suitable solvent and allow to

air dry.
2. Inspect all parts for wear or damage. Repair or
replace as necessary.
3. Inspect crankshaft journals for burrs, nicks,
scratches and wear marks. If wear or damage is
evident, replace the crankshaft.
4. Inspect the machined surfaces of the connecting
rod and cap for burrs, nicks, scratches and wear
marks. If wear or damage is evident, replace the
connecting rod and cap as a set.
5. Inspect the reed valve for cracks or distortion.
Replace as necessary.
6. Inspect the piston and cylinder for wear or damage.
Replace as necessary.
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A.20.A / 41
Air compressor - Assemble (A.20.A.31 - F.10.A.20)

CS540, CS640, CS520, CS660
IMPORTANT: Thoroughly lubricate ALL compressor parts with clean engine oil prior to assembly.
1. Install the connecting rod (1) into the piston (2) in
the same orientation as in disassembly.
20014965 1
2. Install the wrist pin (1) through the piston (2) and
connecting rod.
20014964 2
3. Install a new wrist pin retaining ring (1) on each side

of the piston (2).
NOTE: When installing new wrist pin retaining rings, be
sure to position the opening of the ring facing the top of
the piston.
20013227 3
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A.20.A / 42
4. Be sure to align the connecting rod cap (1) and

connecting rod (2) in the proper orientation to each
other during assembly.
20014966 4
5. Install the crankshaft (1) and connecting rod cap (2)

into the compressor housing as an assembly.
NOTE: Position the gap in the piston rings 120 ° from
each other with no gaps directly above the wrist pin holes
in the piston, before installation into the cylinder.
20014967 5
6. Use a piston ring compressor tool (1) to compress

the piston rings prior to installation of the piston and
connecting rod in the cylinder.
With the piston rings compressed, carefully push
the piston into the cylinder.
20014968 6
7. Install the two connecting rod bolts through the frost

plug holes to attach the connecting rod cap to the
connecting rod. Use a Torx bit to tighten the bolts
gradually and evenly. Tighten the bolts with a torque
to 6 Nm (4.2 lb ft.).
20013223_88 7
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8. Install a new crankshaft seal (1) and the O-ring (2)

onto the end cap (3).
Lubricate the crankshaft seal and the O-ring with
petroleum jelly and install the end cap over the
crankshaft and onto the compressor.
20013222_89 8
9. Install two new 16 mm frost plugs (1) into the

bottom of the compressor housing. Procure the
frost plugs locally.
20013221 9
10. Install the end cover (1) and secure it with the four
mounting bolts (2). Tighten the bolts securely.
20013220_90 10
11. Install a new gasket (1) onto the top of the cylinder.
Install the reed valve (2) onto the top of the cylinder.
20013218_91 11
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A.20.A / 44
12. Install a new gasket (1) onto the manifold plate (2).
Position the manifold plate (2) onto the cylinder,
making sure to align the two pins (3) with the holes
(4) in the reed valve beneath the manifold plate (2).
20013217_92 12
13. Install the valve plate (1), the washer (2) and the
retaining plate (3) onto the manifold plate (4).
20013216_93 13
14. Install the two bolts (1) and the spacers (2) into the
manifold plate. Tighten the bolts securely.
20013215 14
15. Carefully place the cylinder head (1) onto the

manifold plate (2).
20013214_94 15
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16. Install the four cylinder head bolts (1) into the
cylinder head and lightly hand tighten the bolts
evenly.
20013213 16
17. Tighten and torque the cylinder head bolts in the

sequence 1-2-3-4, to 20 Nm (14.8 lb ft.).
20013207 17
18. Install and tighten the four nuts (1) washer

and socket head cap screws (2) securing the
compressor to the mount plate (3).
20014972 18
19. Install the pulley (1) onto the tapered shaft (2).
20013212 19
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20. Install the nut (1) and the washer (2), securing the
pulley (3) to the compressor drive shaft.
Tighten and torque the nut (1) to 100 Nm (73.8 lb ft).
20013211 20
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Air compressor - Install (A.20.A.31 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Position the compressor onto the mount plate and

install the tension adjustment bolt (2).
Install the drive belt (3) onto the air compressor
pulley and engine crankshaft pulley.
ZDA7713A_87 1
2. Install and lightly tighten the three air compressor

mounting nuts (1) and turn the tension adjustment
bolt (2) clockwise to tighten the tension on the air
compressor drive belt (3). When adjusted properly,
the belt deflection should be 3 mm (1/8 in) at the
mid point of the belt when a force of 23 N (5.2 lb) is
applied to the belt.
When adjustment is correct, tighten the mounting
nuts securely.
ZDA7588A 2
3. Connect the oil hoses (2) to the air compressor (3).

Tighten the fittings (1) securely.
Connect the hose (5) to the air compressor (3).
Tighten the hose clamp (4).
ZDA7787A 3
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A.20.A / 48
4. Install the shielding (1) and tighten the bolts.
ZDA7586A 4
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Air compressor - Troubleshooting (A.20.A.31 - G.40.A.10)

CS540, CS640, CS520, CS660
Problem Possible Cause Correction

Compressor will not build Drive belt out of adjustment Adjust drive belt to specs (Refer to
pressure to charge air Air compressor - Install (A.20.A.31 -
tank F.10.A.15)
Drive belt worn or damaged Replace drive belt
Drain valve not closed on the air tank Close air tank drain valve
Loose air line fittings Check and tighten air line fittings
Faulty pressure relief valve Replace pressure relief valve
Worn or damaged internal parts in Remove and rebuild compressor
compressor
Compressor is noisy Engine oil level too low Check engine oil level and fill to specs
Clogged oil line Remove and clean oil lines
Loose compressor mounting bolts Tighten mounting bolts
Drive pulley retaining nut is loose or Tighten drive pulley retaining nut to proper
improperly torqued on the crankshaft torque (Refer to Air compressor - Torque
(A.20.A.31 - D.20.A.10)
Drive pulley worn Replace drive pulley
Compressor slow to build Loose air line fittings Tighten fittings
air pressure
Air tank reservoir drain not closed properly Close air tank reservoir drain properly
Faulty pressure relief valve Replace pressure relief valve
Worn or damaged internal parts in Remove and rebuild compressor
compressor
Compressor builds too Pressure relief valve faulty Replace pressure relief valve
much pressure
12118 1 02/07/2004
A.20.A / 50
Index
Air compressor - Assemble (A.20.A.31 - F.10.A.20) 42

CS540, CS640, CS520, CS660
Air compressor - Disassemble (A.20.A.31 - F.10.A.25) 35
CS540, CS640, CS520, CS660
Air compressor - General specification (A.20.A.31 - D.40.A.10) 4
CS540, CS640, CS520, CS660
Air compressor - Install (A.20.A.31 - F.10.A.15) 48
CS540, CS640, CS520, CS660
Air compressor - Overhaul (A.20.A.31 - F.10.A.40) 41
CS540, CS640, CS520, CS660
Air compressor - Remove (A.20.A.31 - F.10.A.10) 33
CS540, CS640, CS520, CS660
Air compressor - Special tools (A.20.A.31 - D.20.A.40) 4
CS540, CS640, CS520, CS660
Air compressor - Static description (A.20.A.31 - C.30.A.20) 17
CS540, CS640, CS520, CS660
Air compressor - Torque (A.20.A.31 - D.20.A.10) 4
CS540, CS640, CS520, CS660
Air compressor - Troubleshooting (A.20.A.31 - G.40.A.10) 50
CS540, CS640, CS520, CS660
Air tank - Install (A.20.A.22 - F.10.A.15) 32
CS540, CS640, CS520, CS660
Air tank - Remove (A.20.A.22 - F.10.A.10) 31
CS540, CS640, CS520, CS660
Command valve - Assemble (A.20.A.12 - F.10.A.20) 26
CS540, CS640, CS520, CS660
Command valve - Disassemble (A.20.A.12 - F.10.A.25) 25
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Command valve - Static description (A.20.A.12 - C.30.A.20) 15
CS540, CS640, CS520, CS660
PNEUMATIC SYSTEM - Component localisation (A.20.A - C.40.B.20) 10
CS540, CS640, CS520, CS660
PNEUMATIC SYSTEM - Overview (A.20.A - C.10.A.10) 12
CS540, CS640, CS520, CS660
PNEUMATIC SYSTEM - Pneumatic schema (A.20.A - C.20.B.30) 5
CS540, CS640, CS520, CS660
PNEUMATIC SYSTEM - Static description (A.20.A - C.30.A.20) 9
CS540, CS640, CS520, CS660
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Relief valve - Install (A.20.A.16 - F.10.A.15) 30
CS540, CS640, CS520, CS660
Relief valve - Remove (A.20.A.16 - F.10.A.10) 29
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Sensing system Pressure switch - Static description (A.20.A.95.81 - C.30.A.20) 18
CS540, CS640, CS520, CS660
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A.20.A / 52
ELECTRICAL POWER SYSTEM - 30.A
CS540
CS640
CS520
CS660
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A.30.A / 1
Contents
TECHNICAL DATA
ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40) 6

CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - General specification (A.30.A - D.40.A.10) 7
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
ELECTRICAL POWER SYSTEM - Component localisation (A.30.A - C.40.B.20) 16

CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Component identification (A.30.A - C.40.C.20) 26
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Component diagram frame 01 (A.30.A - C.20.F.01) 36
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
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A.30.A / 2
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Electrical standard (A.30.A - C.20.D.40) 321
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Electrical symbol (A.30.A - C.20.C.40) 328
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Electrical schematic frame 01 (A.30.A - C.20.E.01) 346
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
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A.30.A / 3
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Wiring harness
Wiring harness - Overview (A.30.A.88 - C.10.A.10) 469
CS540, CS640, CS520, CS660
SERVICE
ELECTRICAL POWER SYSTEM - Service instruction (A.30.A - F.10.A.05) 478

CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Preliminary test (A.30.A - F.40.A.20) 480
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Adjust (A.30.A - F.45.A.01) 483
CS540, CS640, CS520, CS660
Alternator drive system

Alternator drive system Belt tensioner - Remove (A.30.A.40.49 - F.10.A.10) 484
CS540, CS640, CS520, CS660
Alternator drive system Belt tensioner - Check (A.30.A.40.49 - F.40.A.11) 485
CS540, CS640, CS520, CS660
Alternator drive system Belt tensioner - Install (A.30.A.40.49 - F.10.A.15) 486
CS540, CS640, CS520, CS660
Alternator drive system Idler pulley - Check (A.30.A.40.57 - F.40.A.11) 487
CS540, CS640, CS520, CS660
Wiring harness
Wiring harness - Replace (A.30.A.88 - F.10.A.30) 488
CS540, CS640, CS520, CS660
Wiring harness - Repair (A.30.A.88 - F.75.C.32) 490
CS540, CS640, CS520, CS660
DIAGNOSTIC
ELECTRICAL POWER SYSTEM - Problem solving (A.30.A - G.40.A.30) 492

CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Testing (A.30.A - G.40.A.20) 495
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Alternator
Alternator - Testing (A.30.A.82 - G.40.A.20) 497
CS540, CS640, CS520, CS660
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A.30.A / 4
Alternator - Problem solving (A.30.A.82 - G.40.A.30) 499
CS540, CS640, CS520, CS660
Battery
Battery - Bad voltage (A.30.A.83 - G.30.B.31) 500
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
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A.30.A / 5
DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40)

CS540, CS640, CS520, CS660

Harness repair kit 380030042
Test probe kit 297448
Pin removal tool, Bosch module connector 84021087
Deutsch extraction tool 84400044
Deutsch contact crimp tool 84400045
Deutsch retraction tool, DT series wedge 84400046
Packard contact crimp tool 84400047
Packard terminal removal tool 84400048
Digital multimeter OEM 1428A.
55_3_55_3_01 1
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A.30.A / 6
ELECTRICAL POWER SYSTEM - General specification (A.30.A -

D.40.A.10)
CS540, CS640, CS520, CS660
Fuses
Fuses protect circuits with thin pieces of metal and wire
which heat up and melt to open up the circuit when too
much current flows through them.
Fuses are used to protect the circuit from overload. This
can occur in the event of a short circuit or by connecting
equipment which demands a current greater than the
circuit is designed to carry.
There are several types of fuses, but they all consist of
a metal conductor which is capable of carrying a limited
current. If the specified current is exceeded then the
metal conductor will overheat, causing it to melt and
break. This will in turn cause an open circuit.
The rating of the fuse relates to the current that the fuse
ZDF0223A 1
can carry continuously.
If a fuse blows, it must be replaced with a fuse of the
correct rating, and if it blows again, then the cause must
be investigated.
A fuse may be tested by checking continuity across the
fuse on the two exposed terminals (1).
Fuses and relays are located on different places of the
combine:
1. Armrest printed circuit: located in the dashboard.
50014700 2
2. Fuse printed circuit: located at the backside at the

right-hand side of the cab.
ZDA5914A 3
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A.30.A / 7
3. Cab roof printed circuit: located at the right-hand side

of the roof.
ZDA5916A 4
4. Fuses and relays located in the battery compartment.
ZDA5913A 5
5. Fuses and relays located on the engine module.
ZDA6031A 6
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Switches
Switches are a vital part of an electric circuit, providing
a method of controlling the circuit itself. One switch
can control a number of different circuits at the same
time. This is achieved by having several separate
connections and/or multi-connector switches (several
switch positions).
There are several types of switches, and they may
incorporate a warning light.
ZDA6613A 7
Switches can be as simple as that used to turn on an

implement lamp or as complex as the ones used to
operate the starting and lighting systems. Checking the
operation of switches is usually just a matter of testing
for power going into the switch and for power leaving
the switch at the appropriate contacts when the switch
is operated.
One of the most common type of switches is the pressure
switch, a switch opened or closed by a fluid pressure. An
example of this type of switch is the charge pressure
switch, a simple on/off device that opens (or closes)
when oil pressure rises or lowers past a preset value.
ZDA6443B 8
Flashers
Flashers work automatically to interrupt and connect the
flow of current.
In the flasher, a heating element warms a bimetallic strip.
The strip bends, breaking contact with the power source.
When it cools, the bimetallic strip once again makes
contact and the process begins again.
55_3_55_3_30 9
Resistance devices
A number of electrical components alter or make use
of electricity through their resistance to current flow.
Resistors are components which are generally used
to regulate the supply of voltage and current to other
electrical components.
In some cases, the purpose of resistance in an electrical
circuit is to provide light or heat. Lamps and cigar lighters
are examples. Lamps convert electricity into light, and
cigar lighters convert it into heat. Both lamps and lighters
make use of the same physical principle, that is Ohms
Law.
55_3_55_3_31 10
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A.30.A / 9
Fluid level sender

It operates by varying resistance through the movement
of a float. An example is the fuel level sender.
55_3_55_3_32 11
Potentio meters
Potentio meters are variable resistors which are
dependant on mechanical movement, i.e. Lateral float
movement, to vary the resistance of the component and
therefore alter the output voltage.
In order to verify the correct operation of a potentio
meter, the resistance should be measured at the
minimum and maximum positions and a smooth and
continuous change of resistance should be observed
between. As the resistance varies with temperature, the
test specifications are usually given at 20 °C.
55_3_55_3_33 12
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Electromagnetic devices
In general, they use the magnetic field created by flowing
current to move metal parts within the components.
Relays
The relay is an electromagnetic switch that uses a small
amount of current to switch a larger amount on and off.
When the operator closes a switch, current flows through
the relay’s control circuit. In this circuit there are windings
surrounding an iron core which is fixed in place.
Current turns the iron core into an electromagnet. The
core then attracts an arm which has a contact point on it.
When the point on the arm contacts the stationary point,
current flows through the power circuit.
Relays are basically electrically operated switches. They
ZDA6656C 13
are used to switch a circuit on/off in similar way to a
manual switch.
Two circuits are connected to the relay:
• A work circuit, which is switched on/off by the relay,

and provides the supply for the equipment to be
operated, i.e., bulbs, solenoids, etc.;
• A control circuit, switched on/off by manual

switches, used to operate the relay.
The part of the relay which is connected to the control
circuit consists of the winding of an electro-magnet.
When the control circuit is switched off, the contacts are
kept apart by a return spring. When the control circuit
is switched on, a current flows through the coil and a
magnetic force is produced. This force, which is stronger
than the spring pressure, pulls the contacts of the relay
together, causing the work circuit to operate.
A switch-relay system has two main advantages over
a simple switch:
• The current that flows through the switch is not the

same as all the current requested by the equipment
to be operated, but usually by a smaller current:
this allows the usage of smaller and less expensive
switches;
• The distance from the supply, to the equipment,

can be made as short as possible to minimise
voltage drop.
55_3_55_3_37 14
There are different styles of relays used on the CS

combine. The micro relay (1) is the most commonly used
relay, the mini relay (2) and the time delay relay (3).
On the relay cover there are terminal markings:
3 or 30: input terminal direct from battery positive,

normally live.
• 2 or 85: winding output terminal, usually to ground.
• 1 or 86: winding input terminal.
• 4 or 87: output terminal for normally closed contact.
• 5 or 87a: output terminal for normally open contact. 55_3_55_3_38 15
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Solenoids
Solenoids work in much the same way as relays, except
that the iron core is not fixed in place. As a result, the
windings in the control circuit cause the iron core to
move.
In the starting system, for example, the movement of
this core is used to send large amounts of current to the
starter motor.
A solenoid is basically a winding around an iron core. In
the centre of the core there is a plunger which is free
to move through the core. When an electrical current
passes through the winding an electro-magnetic force is
produced which causes the plunger to move through the
core. If the current is switched off, the magnetic force is
50004701 16
stopped and the plunger is returned by a spring.
The solenoid plunger may have different uses: the most
common are moving a hydraulic spool or a mechanical
lever.
The MOST COMMON FAULTS that can occur are:
• Short circuit winding: if a section of the winding

allows the current to pass directly from positive (+)
to negative (-) terminals without passing through
the winding, this will cause the relevant circuit fuse
to blow.
• Broken winding: causing an open circuit, it will not

allow the current to pass through the winding, so
the solenoid will not operate.
• Seized plunger (and/or connected component):

the solenoid will only move the plunger if all
components are free to move.
PWM solenoid valves

Whenever it is necessary to provide proportional control
to the solenoid valves, it is much better to use a principle
of operation called pulse width modulation (PWM). PWM
is a variable DC voltage signal that is used to control the
solenoid valves. The voltage signal is pulsed on and off
many times a second (at a constant frequency of 500
Hz) at a constant supply voltage of 12 V.
55_3_55_3_40 17
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A.30.A / 12
The CCM module (1) contain transistors that are supplied

with a constant input voltage which is switched on and
off to achieve the variable input range. In this way the
control module is able to limit the armature movement, so
the hydraulic output flow of the solenoid is proportional to
the average DC voltage. The lower voltage also allows
the solenoid to operate with less residual magnetism and
so the entire circuit will operate smoother.
The variable DC voltage signal level is determined by
varying the duration of the ON pulse relative to the OFF
pulse. The ratio between the ON time and the cycle time
is called duty cycle and is stated as a percentage of one
complete cycle.
55_3_55_3_41 18
Diagrams, (1) to (3), show the normal operating range of

the PWM valve, and diagram (4), shows the initial 12 V
programming and fill time only. The diagrams in column
"A" show the voltage signal that is sent to the valve,
whereas column "B" shows the relevant spring pressure
and column "C" the reading on a volt meter connected
to the solenoid valve.
Diagram (1) shows the OFF position: no signal is
directed to the valve, which means no spring pressure
in the valve at all and results in a zero voltage reading.
Increasing the duty cycle causes some pressure to be
made on the circuit (Diagram (2)), which results in a
voltmeter reading increase. Diagram (3) shows the
55_3_55_3_42 19
maximum signal that is used during the normal activity of
the valve: its duty cycle is around 0.5, which results in a
spring pressure for the half of its run and in an indication
of a 6 volt average DC current.
The electrical circuit to the solenoids can be checked
by using a digital or analogue DC voltmeter, which will
indicate the average voltage readings.
Sensors
A sensor is the primary component of a measurement
chain that converts the input variable (temperature,
capacitance, reluctance) into a signal suitable for
measurement. The relationship between the input
variable and the measured signal is a characteristic of
the sensor.
In the above mentioned measurement chain the signal
is filtered and treated in order to adapt it to its use.
It consists of three elements: the sensor itself; the
converter, which converts the output signal from the
sensor (in most of the cases into an electric signal); and
the conditioner, which transforms the output signal from
the converter in the most suitable form. Generally the
term sensor indicates the entire measurement chain.
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A.30.A / 13
Temperature sensors
Generally based on a simple circuit with a thermistor.
A thermistor is a resistor that changes its resistance
according to the temperature.
There are two groups of thermistors: NTC (Negative
Temperature Coefficient) and PTC (positive Temperature
Coefficient). In the first case the higher the temperature,
the lower is the resistance, and for the PTC the higher
the temperature, the higher the resistance. The NTC are
often used as sensors to indicate temperature change in
fluids, such as the engine coolant fluid.
An example of these type of senders is the coolant
temperature sender. The changes in its resistance
(which varies with temperature) are relayed to the
ZDA5917A 20
monitor, which operates the bargraph and the warning
indicators accordingly.
Pressure sender
A pressure sender receives a supply signal and it varies
it according to the (oil) pressure. An example is the oil
pressure sender, which receives a 5 volt signal and
varies it according to the oil pressure. The appropriate
module keeps track of these variations and changes its
readouts and warnings accordingly.
55_3_55_3_44 21
Speed and position sensors

The speed and position sensors used on the CS combine
are a two-wire sensing device designed to work with a
switching amplifier circuit in the module the sensor is
attached to.
The operation of this sensor is similar to that of a
variable resistor, which changes its impedance as metal
approaches the sensor. When no metal is being sensed,
the sensor is in a low impedance state. When metal
approaches the sensor, the impedance increases. The
varying impedance results in a current flow change that
the module detects, and converts into a frequency for
speed sensing or position monitoring.
When installing a new sensor, adjust the sensor to obtain
55_3_55_3_45 22
a clearance of 3 mm (1/8 in) to the target metal.
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Electronic module (CCM)

The electronic module (1) is the “black box" that provide
control on many of the functions of the combine.
Inside the “black box" there is a processor, the "thinking
part" of the module, and inside there is one or more
memories, which may allow the module to store
calibration values, the configuration of the vehicle and
the error codes.
55_3_55_3_46 23
A processor has a series of pins, which are electrical

contacts. There are three main types of pins: for
the inputs of the signals, for the outputs and for the
processor supply.
The processor, the memories and the link between them
form the hardware of the module, its "physical" part.
Then some software is needed, to handle the
communication between the processor and the
memories and to manage the various signals going into
and out of the processor. The software is designed to
operate in a different way and is called functional code.
The electronic module is often blamed as responsible
for most of the problems of the modern vehicles, while
55_3_55_3_47 24
they are for certain among the most protected parts of
the vehicle. In fact, the pins of the module are protected
against spikes (high pulses) of current, and the signals
are filtered by the hardware and by the software in input
and in output to give the best handling of information.
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ELECTRICAL POWER SYSTEM - Component localisation (A.30.A -

C.40.B.20)
CS540, CS640, CS520, CS660
NOTE: All components have been grouped by general location on the combine.
CAB AREA
Inner cab
Inclinometer (A2)
ZVE0143B 1
Steering column printed circuit (A3)
VFIL04CS0147A0A 2
CCM module (A8)
ZVE0209B 3
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Radio (A20)
VFIL04CS0150A0A 4
A-post module (A25)
VFIL04CS0149B0A 5
Cab roof
Blower (A23)
Wiper motor (M8)
ZVE0279A 6
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Under cab
Horn (B22)
Brake switch (S52)
Brake solenoid (Y1)
ZVE0271A 7
Cab left (Operator’s platform)
Reel up solenoid (Y5)

Unloading tube open solenoid (Y6)
Unloading tube close solenoid (Y7)
Reversing mechanism solenoid (Y10)
Reversing mechanism solenoid (Y12)
Reel forward solenoid (Y13)
Reel rearward solenoid (Y14)
Header up solenoid (Y18)
Header Down Solenoid (Y19)
ZVE0242A 8
RIGHT-HAND SIDE
Behind front wheel
Fan speed variator motor (M4)
ZVE0268A 9
Header height sensor (R2)
ZVE0156B 10
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Fuel tank
Fuel level potentiometer (R6)
ZVE0273A 11
Rear
Reverse drive buzzer (B1)
ZVE0130B 12
Ladder safety switch (S10)
ZVE0270A 13
LEFT-HAND SIDE
Elevator
Lateral float solenoid (left down) (Y16)

Lateral Float Solenoid (Right Down) (Y17)
ZVE0293A 14
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Behind front wheel
Unloading tube protection switch (S32)

Returns elevator speed sensor (B12)
Drum variator speed sensor (B9)
ZVE0277A 15
Rotary separator speed sensor (B11)

Drum variator motor (M3)
ZVE0276A 16
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Middle
Fan variator speed sensor (B8)
ZVE0275A 17
Straw walker speed sensor (B13)
ZVE0274A 18
Unloading tube engagement solenoid (Y8)

Straw elevator engagement solenoid (Y9)
Threshing mechanism engagement (Y15)
ZVE0374A 19
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ENGINE COMPARTMENT
Engine temperature sensor (R5)

Engine coolant temperature contact (B2)
Alternator (G3)
Air conditioning high pressure contact
(B71)
ZVE0267A 20
Engine stop solenoid (Y3)

Starter motor (M1)
ZVE0272A 21
Hydrostatic oil temperature contact (B17)
ZVE0269A 22
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Cold start heating element (R11)
VFIL04CS0111A0A 23
Pre-heating fuel pump solenoid (Y23)
VFIL04CS0155A0A 24
UNDER COMBINE
Front (above axle)
Header pressure sensor (B18)

Compensation valve header height control
solenoid (Y20)
ZVE0298A 25
Rear
Sieves grain loss sensor (B21)
ZVE0175B 26
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Middle
Self-levelling actuator (M6)
ZVE0221B 27
REAR HOOD
Inner right
Straw walker grain loss sensor (B19)
ZVE0173B 28
Inner left
Straw walker grain loss sensor (B20)
ZVE0174B 29
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Rear
Spreader plate actuator (M7)
ZVE0302B 30
HEADER
Left-hand side
Reel speed variator motor (M5)
ZVE0371A 31
STRAW ELEVATOR
Right-hand side
Electrical header reversing starter motor

(M2)
VFIL04CS0112A0A 32
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ELECTRICAL POWER SYSTEM - Component identification (A.30.A -

C.40.C.20)
CS540, CS640, CS520, CS660
Connector
Code Description Reference
X002 IN-LINE HARNESS CONNECTOR ELECTRICAL POWER SYSTEM - Component
(MAIN POWER SUPPLY) diagram frame 01 (A.30.A-C.20.F.01)
X004 A POST MODULE (A25) ELECTRICAL POWER SYSTEM - Component
diagram frame 01 (A.30.A-C.20.F.01)
X006 BRAKE SOLENOID (Y1) ELECTRICAL POWER SYSTEM - Component
(STEERING COLUMN) diagram frame 16 (A.30.A-C.20.F.16)
diagram frame 06 (A.30.A - C.20.F.06)
X009 12 V CONNECTOR ELECTRICAL POWER SYSTEM - Component
X011 REVERSE DRIVE BUZZER (B1) ELECTRICAL POWER SYSTEM - Component
(SOLENOID VALVES) diagram frame 05 (A.30.A-C.20.F.05)
(POWER REAR AXLE SOLENOID) diagram frame 24 (A.30.A-C.20.F.24)
X014 ENGINE STOP SOLENOID (Y3) ELECTRICAL POWER SYSTEM - Component
X015 PRINTED CIRCUIT (REAR LIGHTS) ELECTRICAL POWER SYSTEM - Component
X017 DRUM VARIATOR MOTOR (M3) ELECTRICAL POWER SYSTEM - Component
X018 FAN VARIATOR MOTOR (M4) ELECTRICAL POWER SYSTEM - Component
X019 HEADER CONNECTOR ELECTRICAL POWER SYSTEM - Component
X020 REEL VARIATOR MOTOR (M5) ELECTRICAL POWER SYSTEM - Component
X021 REEL SYNCHRONIZATION ELECTRICAL POWER SYSTEM - Component
SOLENOID (Y21) diagram frame 10 (A.30.A-C.20.F.10)
(SPREADER PLATES) diagram frame 12 (A.30.A-C.20.F.12)
X023 INCLINOMETER (A2) ELECTRICAL POWER SYSTEM - Component
(SELF LEVELLING CLEANING diagram frame 13 (A.30.A-C.20.F.13)
SYSTEM)
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(GROUND) diagram frame 01 (A.30.A-C.20.F.01)
X027 GROUNDSPEED SENSOR (B7) ELECTRICAL POWER SYSTEM - Component
X028 FANSPEED SENSOR (B8) ELECTRICAL POWER SYSTEM - Component
X029 DRUMSPEED SENSOR (B9) ELECTRICAL POWER SYSTEM - Component
X030 STRAW CHOPPER SPEED SENSOR ELECTRICAL POWER SYSTEM - Component
(B10) diagram frame 15 (A.30.A-C.20.F.15)
X031 STRAW WALKER PROTECTION ELECTRICAL POWER SYSTEM - Component
SWITCH (S23) diagram frame 14 (A.30.A-C.20.F.14)
X032 ROTARY SEPARATOR SPEED ELECTRICAL POWER SYSTEM - Component
SENSOR (B11) diagram frame 15 (A.30.A-C.20.F.15)
X033 RETURNS ELEVATOR SENSOR ELECTRICAL POWER SYSTEM - Component
X034 LADDER SWITCH (S10) ELECTRICAL POWER SYSTEM - Component
X035 DIAGNOSTIC PLUG ELECTRICAL POWER SYSTEM - Component
X036 UNLOADING TUBE ENGAGEMENT ELECTRICAL POWER SYSTEM - Component
AND REEL FWD/RWD SWITCHES diagram frame 05 (A.30.A - C.20.F.05)
(S33, S4, S6)
X037 STRAW WALKER SPEED SENSOR ELECTRICAL POWER SYSTEM - Component
X039 HEADER HEIGHT SENSOR (R2) ELECTRICAL POWER SYSTEM - Component
X041 GRAIN TANK LEVEL 1 SWITCH (S35) ELECTRICAL POWER SYSTEM - Component
X042 GRAIN TANK LEVEL 2 SWITCH (S36) ELECTRICAL POWER SYSTEM - Component
X043 RIGHT HAND VERTICAL KNIFE ELECTRICAL POWER SYSTEM - Component
RELAY (K71) diagram frame 24 (A.30.A-C.20.F.24)
X044 LEFT HAND VERTICAL KNIFE ELECTRICAL POWER SYSTEM - Component
RELAY (K70) diagram frame 24 (A.30.A-C.20.F.24)
X045 PRINTED CIRCUIT (RIGHT HAND ELECTRICAL POWER SYSTEM - Component
SIDE FRONT LIGHTS) diagram frame 16 (A.30.A-C.20.F.16)
X046 LEFT HAND SIDE FRONT LIGHTS ELECTRICAL POWER SYSTEM - Component
(E5) diagram frame 16 (A.30.A - C.20.F.16)
X047 RIGHT HAND SIDE FRONT LIGHTS ELECTRICAL POWER SYSTEM - Component
(E10) diagram frame 16 (A.30.A - C.20.F.16)
X049 WARNING INDICATOR PRINTED ELECTRICAL POWER SYSTEM - Component
CIRCUIT diagram frame 16 (A.30.A-C.20.F.16)
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X052 HEADER HEIGHT CONTROL ELECTRICAL POWER SYSTEM - Component
PRINTED CIRCUIT diagram frame 07 (A.30.A-C.20.F.07)
X053 RIGHT HAND SIDE STRAW WALKER ELECTRICAL POWER SYSTEM - Component
GRAIN LOSS SENSOR (B19) diagram frame 15 (A.30.A-C.20.F.15)
X054 LEFT HAND SIDE STRAW WALKER ELECTRICAL POWER SYSTEM - Component
GRAIN LOSS SENSOR (B20) diagram frame 15 (A.30.A-C.20.F.15)
X055 SIEVES GRAIN LOSS SENSOR ELECTRICAL POWER SYSTEM - Component
X056 SPREADER PLATE ACTUATOR ELECTRICAL POWER SYSTEM - Component
(M7/R7) diagram frame 12 (A.30.A-C.20.F.12)
X057 TRAILER SOCKET ELECTRICAL POWER SYSTEM - Component
X059 ROAD LIGHTS, FRONT, LEFT HAND ELECTRICAL POWER SYSTEM - Component
X062 ROAD LIGHTS, FRONT, RIGHT ELECTRICAL POWER SYSTEM - Component
HAND diagram frame 16 (A.30.A-C.20.F.16)
X065 ADDITIONAL RIGHT HAND REAR ELECTRICAL POWER SYSTEM - Component
PARK LIGHT diagram frame 16 (A.30.A-C.20.F.16)
X066 LEFT HAND SIDE HEADLAMP (E12) ELECTRICAL POWER SYSTEM - Component
X067 RIGHT HAND SIDE HEADLAMP ELECTRICAL POWER SYSTEM - Component
(E13) diagram frame 16 (A.30.A-C.20.F.16)
(REAR WORK LIGHT) diagram frame 20 (A.30.A-C.20.F.20)
X074 STRAW HOOD REVOLVING ELECTRICAL POWER SYSTEM - Component
FLASHING LIGHT (E2) diagram frame 19 (A.30.A-C.20.F.19)
X075 PRE-HEATING FUEL PUMP ELECTRICAL POWER SYSTEM - Component
X080 12 V PLUG ELECTRICAL POWER SYSTEM - Component
X081 BLOWER FAN (A23) ELECTRICAL POWER SYSTEM - Component
X082 CLIMATE CONTROL MODULE (A24) ELECTRICAL POWER SYSTEM - Component
(LEFT HAND SIDE STRAW WALKER diagram frame 15 (A.30.A-C.20.F.15)
GRAIN LOSS SENSOR)
X085 STRAW WALKER PROTECTION ELECTRICAL POWER SYSTEM - Component
X087 CIGARETTE LIGHTER ELECTRICAL POWER SYSTEM - Component
X088 HEADER PRESSURE SENSOR ELECTRICAL POWER SYSTEM - Component
X089 THRESHING ENGAGEMENT ELECTRICAL POWER SYSTEM - Component
X090 HEADER ENGAGEMENT SWITCH ELECTRICAL POWER SYSTEM - Component
(S16) diagram frame 09 (A.30.A-C.20.F.09)
X092 UNLOADING TUBE PROTECTION ELECTRICAL POWER SYSTEM - Component
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X093 REVOLVING FLASHING LIGHT (CAB ELECTRICAL POWER SYSTEM - Component
ROOF) (E1) diagram frame 19 (A.30.A-C.20.F.19)
(LIGHTS) diagram frame 20 (A.30.A-C.20.F.20)
X097 SWATH PLATE POSITION SENSOR ELECTRICAL POWER SYSTEM - Component
(STRAW CHOPPER POSITION diagram frame 15 (A.30.A-C.20.F.15)
SENSOR)
X102 ROTARY DUST SCREEN BRUSH ELECTRICAL POWER SYSTEM - Component
(M14) diagram frame 10 (A.30.A-C.20.F.10)
X104 LEFT HAND SIDE MIRROR (M13) ELECTRICAL POWER SYSTEM - Component
X105 RIGHT HAND SIDE MIRROR (M12) ELECTRICAL POWER SYSTEM - Component
X106 ADDITIONAL MIRROR (GERMAN) ELECTRICAL POWER SYSTEM - Component
(M11) diagram frame 22 (A.30.A-C.20.F.22)
X107 RADIO (A20) ELECTRICAL POWER SYSTEM - Component
X109 WINDSCREEN WIPER MOTOR (M8) ELECTRICAL POWER SYSTEM - Component
X111 FUSE PRINTED CIRCUIT ELECTRICAL POWER SYSTEM - Component
X120 FUSE PRINTED CIRCUIT (TO BE ELECTRICAL POWER SYSTEM - Component
DELETED) diagram frame 20 (A.30.A-C.20.F.20)
X121 FUSE PRINTED CIRCUIT (RIGHT ELECTRICAL POWER SYSTEM - Component
HAND CONSOLE) diagram frame 06 (A.30.A-C.20.F.06)
X122 FUSE PRINTED CIRCUIT (RIGHT ELECTRICAL POWER SYSTEM - Component
HAND CONSOLE) diagram frame 05 (A.30.A-C.20.F.05)
X123 MULTIFUNCTION HANDLE ELECTRICAL POWER SYSTEM - Component
X125 LIGHTS PRINTED CIRCUIT ELECTRICAL POWER SYSTEM - Component
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X137 PRINTED CIRCUIT (BRAKE LIGHTS) ELECTRICAL POWER SYSTEM - Component
(ROTARY DUST SCREEN BRUSH) diagram frame 10 (A.30.A-C.20.F.10)
X139 PRINTED CIRCUIT (LEFT HAND ELECTRICAL POWER SYSTEM - Component
SIDE FRONT LIGHTS) diagram frame 16 (A.30.A-C.20.F.16)
X140 LEFT HAND SIDE FRONT ELECTRICAL POWER SYSTEM - Component
ADDITIONAL LIGHTS (E6) diagram frame 16 (A.30.A-C.20.F.16)
X141 CCM-MODULE (A8) ELECTRICAL POWER SYSTEM - Component
(REAR LIGHTS) diagram frame 16 (A.30.A-C.20.F.16)
X145 RIGHT HAND SIDE FRONT ELECTRICAL POWER SYSTEM - Component
ADDITIONAL LIGHTS (E11) diagram frame 16 (A.30.A-C.20.F.16)
X147 REEL SPEED SENSOR (B27) ELECTRICAL POWER SYSTEM - Component
X148 ROAD LIGHTS AND INDICATOR ELECTRICAL POWER SYSTEM - Component
SWITCH (S53/S55) diagram frame 16 (A.30.A-C.20.F.16)
(RIGHT HAND SIDE STRAW diagram frame 15 (A.30.A-C.20.F.15)
WALKER GRAIN LOSS SENSOR)
(LEFT HAND SIDE STRAW WALKER diagram frame 15 (A.30.A-C.20.F.15)
GRAIN LOSS SENSOR)
X154 PRINTED CIRCUIT (REAR ELECTRICAL POWER SYSTEM - Component
DIRECTION INDICATORS) diagram frame 18 (A.30.A-C.20.F.18)
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X155 PNEUMATIC SOLENOIDS ELECTRICAL POWER SYSTEM - Component
(Y8/Y9/Y15) diagram frame 08 (A.30.A-C.20.F.08)
X156 THRESHING MECHANISM ELECTRICAL POWER SYSTEM - Component
PRESSURE SWITCH (S72) diagram frame 08 (A.30.A-C.20.F.08)
X157 SELF-LEVELLING ACTUATOR (M6) ELECTRICAL POWER SYSTEM - Component
X158 SELF-LEVELLING ACTUATOR ELECTRICAL POWER SYSTEM - Component
POTENTIOMETER (R1) diagram frame 13 (A.30.A-C.20.F.13)
X164 RIGHT HAND SIDE REAR ELECTRICAL POWER SYSTEM - Component
OPERATING LIGHT (E28) diagram frame 20 (A.30.A-C.20.F.20)
X165 LEFT HAND SIDE REAR OPERATING ELECTRICAL POWER SYSTEM - Component
LIGHT (E29) diagram frame 20 (A.30.A-C.20.F.20)
X167 BRAKE LINING WARNING SWITCH ELECTRICAL POWER SYSTEM - Component
(S37.1) diagram frame 14 (A.30.A-C.20.F.14)
X176 LEFT HAND SIDE STUBBLE LIGHT ELECTRICAL POWER SYSTEM - Component
X177 RIGHT HAND SIDE STUBBLE LIGHT ELECTRICAL POWER SYSTEM - Component
REVOLVING FLASHING LIGHT diagram frame 19 (A.30.A-C.20.F.19)
(STRAW HOOD)
(LEFT HAND SIDE MIRROR) diagram frame 22 (A.30.A-C.20.F.22)
(RIGHT HAND SIDE MIRROR) diagram frame 22 (A.30.A-C.20.F.22)
X182 AIR CONDITIONING PRESSURE ELECTRICAL POWER SYSTEM - Component
SWITCH (B71/S70) diagram frame 23 (A.30.A-C.20.F.23)
X183 AIR CONDITIONING COMPRESSOR ELECTRICAL POWER SYSTEM - Component
CLUTCH SOLENOID (Y11) diagram frame 23 (A.30.A-C.20.F.23)
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X196 LEFT-HAND SIDE RAILING ELECTRICAL POWER SYSTEM - Component
HEADLIGHTS diagram frame 17 (A.30.A-C.20.F.17)
X197 RIGHT-HAND SIDE RAILING ELECTRICAL POWER SYSTEM - Component
HEADLIGHTS diagram frame 17 (A.30.A-C.20.F.17)
Switch
S1 MAIN BATTERY SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 01 (A.30.A-C.20.F.01)
S2 MULTI-FUNCTION HANDLE ELECTRICAL POWER SYSTEM - Component diagram
NEUTRAL SWITCH frame 01 (A.30.A-C.20.F.01)
S3 KEYSTART SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 01 (A.30.A-C.20.F.01)
S4 REEL FORWARD SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 05 (A.30.A-C.20.F.05)
S5 REVERSE DRIVE BUZZER ELECTRICAL POWER SYSTEM - Component diagram
SWITCH frame 05 (A.30.A-C.20.F.05)
S6 REEL REARWARD SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 05 (A.30.A-C.20.F.05)
S8 POWER REAR AXLE SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 24 (A.30.A-C.20.F.24)
S9 ENGINE PROTECTION RESET + ELECTRICAL POWER SYSTEM - Component diagram
KILL STOP SWITCH frame 04 (A.30.A-C.20.F.04)
S10 LADDER SAFETY SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 08 (A.30.A - C.20.F.08)
S11 REEL DOWN SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 05 (A.30.A-C.20.F.05)
S12 REEL UP SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 05 (A.30.A-C.20.F.05)
S13 UNLOADING TUBE OPEN SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 05 (A.30.A-C.20.F.05)
S14 UNLOADING TUBE CLOSE ELECTRICAL POWER SYSTEM - Component diagram
S15 THRESHING ENGAGEMENT ELECTRICAL POWER SYSTEM - Component diagram
SWITCH frame 08 (A.30.A - C.20.F.08)
S16 HEADER ENGAGEMENT SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 09 (A.30.A - C.20.F.09)
S17 DRUM VARIATOR SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 12 (A.30.A-C.20.F.12)
S18 FAN VARIATOR SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 12 (A.30.A-C.20.F.12)
S20 REEL VARIATOR SLOW SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 10 (A.30.A-C.20.F.10)
S21 REEL VARIATOR FAST SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 10 (A.30.A-C.20.F.10)
S22 STRAW WALKER PROTECTION ELECTRICAL POWER SYSTEM - Component diagram
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S23 STRAW WALKER PROTECTION ELECTRICAL POWER SYSTEM - Component diagram
S25 SELF LEVELLING CLEANING ELECTRICAL POWER SYSTEM - Component diagram
SHOE SWITCH frame 13 (A.30.A-C.20.F.13)
S26 MANUAL CONTROL SELF ELECTRICAL POWER SYSTEM - Component diagram
LEVELLING CLEANING SYSTEM frame 13 (A.30.A-C.20.F.13)
SWITCH
S27 LATERAL FLOTATION LEFT DOWN ELECTRICAL POWER SYSTEM - Component diagram
S28 LATERAL FLOTATION RIGHT ELECTRICAL POWER SYSTEM - Component diagram
DOWN SWITCH frame 06 (A.30.A - C.20.F.06)
S29 HEADER UP SLOW SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 06 (A.30.A - C.20.F.06)
S30 HEADER DOWN SLOW SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 06 (A.30.A - C.20.F.06)
S31 SAFETY ON THE ROAD SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 08 (A.30.A-C.20.F.08)
S32 UNLOADING TUBE PROTECTION ELECTRICAL POWER SYSTEM - Component diagram
S33 UNLOADING TUBE ENGAGEMENT ELECTRICAL POWER SYSTEM - Component diagram
S34 REVOLVING FLASHING LIGHT ELECTRICAL POWER SYSTEM - Component diagram
S35 GRAIN TANK LEVEL 1 SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 19 (A.30.A-C.20.F.19)
S36 GRAIN TANK LEVEL 2 SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 19 (A.30.A-C.20.F.19)
S37 BRAKE LINING WARNING ELECTRICAL POWER SYSTEM - Component diagram
CONTACT frame 14 (A.30.A - C.20.F.14)
S41 BRAKE OIL LEVEL SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 14 (A.30.A - C.20.F.14)
S42 PARKING BRAKE SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 14 (A.30.A - C.20.F.14)
S47 AUTOMATIC HEADER HEIGHT ELECTRICAL POWER SYSTEM - Component diagram
CONTROL SWITCH frame 06 (A.30.A - C.20.F.06)
S48 HEADER HEIGHT MODES ELECTRICAL POWER SYSTEM - Component diagram
SELECTOR SWITCH frame 07 (A.30.A-C.20.F.07)
S49 SPREADER PLATES SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 12 (A.30.A-C.20.F.12)
S50 HEADER UP FAST SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 06 (A.30.A - C.20.F.06)
S51 HEADER DOWN FAST SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 06 (A.30.A - C.20.F.06)
S52 BRAKE LIGHTS SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 16 (A.30.A-C.20.F.16)
S53 ROAD LIGHTS AND INDICATOR ELECTRICAL POWER SYSTEM - Component diagram
S54 HAZARD WARNING LIGHTS ELECTRICAL POWER SYSTEM - Component diagram
S55 DIRECTION INDICATOR ELECTRICAL POWER SYSTEM - Component diagram
frame 18 (A.30.A-C.20.F.18)
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S56 OPERATING LIGHTS SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 20 (A.30.A-C.20.F.20)
S57 CAB DOOR SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 20 (A.30.A-C.20.F.20)
S58 WINDSCREEN WIPER SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 21 (A.30.A-C.20.F.21)
S59 WINDSCREEN WASHER SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 21 (A.30.A-C.20.F.21)
S62 MIRROR ADJUSTMENT SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 22 (A.30.A-C.20.F.22)
S63 ADDITIONAL MIRROR SWITCH ELECTRICAL POWER SYSTEM - Component diagram
(GERMAN) frame 22 (A.30.A-C.20.F.22)
S65 REEL SYNCHRONIZATION ELECTRICAL POWER SYSTEM - Component diagram
S66 COLD START PRE-HEATING ELECTRICAL POWER SYSTEM - Component diagram
S67 STUBBLE LIGHTS SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 20 (A.30.A-C.20.F.20)
S68 SPOT LIGHTS SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 20 (A.30.A-C.20.F.20)
S69 VERTICAL KNIVES SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 24 (A.30.A-C.20.F.24)
S70 LOW PRESSURE CONTACT AIR ELECTRICAL POWER SYSTEM - Component diagram
CONDITIONING frame 23 (A.30.A-C.20.F.23)
S72 THRESHING MECHANISM ELECTRICAL POWER SYSTEM - Component diagram
PRESSURE SWITCH frame 08 (A.30.A-C.20.F.08)
S80 CCM OVERRIDE SWITCH ELECTRICAL POWER SYSTEM - Component diagram
frame 06 (A.30.A - C.20.F.06)
S81 REVERSING MECHANISM ELECTRICAL POWER SYSTEM - Component diagram
Solenoid
Y01 BRAKE SOLENOID ELECTRICAL POWER SYSTEM - Component
Y03 ENGINE STOP SOLENOID ELECTRICAL POWER SYSTEM - Component
Y04 REEL DOWN SOLENOID ELECTRICAL POWER SYSTEM - Component
Y05 REEL UP SOLENOID ELECTRICAL POWER SYSTEM - Component
Y06 UNLOADING TUBE OPEN SOLENOID ELECTRICAL POWER SYSTEM - Component
Y07 UNLOADING TUBE CLOSE SOLENOID ELECTRICAL POWER SYSTEM - Component
Y10 REVERSING MECHANISM SOLENOID ELECTRICAL POWER SYSTEM - Component
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Y11 AIR CONDITIONING COMPRESSOR CLUTCH ELECTRICAL POWER SYSTEM - Component
SOLENOID diagram frame 23 (A.30.A-C.20.F.23)
Y12 REVERSING MECHANISM SOLENOID ELECTRICAL POWER SYSTEM - Component
Y13 REEL FORWARD SOLENOID ELECTRICAL POWER SYSTEM - Component
Y14 REEL REARWARD SOLENOID ELECTRICAL POWER SYSTEM - Component
Y16 LATERAL FLOAT SOLENOID (RIGHT DOWN) ELECTRICAL POWER SYSTEM - Component
Y17 LATERAL FLOAT SOLENOID (LEFT DOWN) ELECTRICAL POWER SYSTEM - Component
Y18 HEADER UP SOLENOID ELECTRICAL POWER SYSTEM - Component
Y19 HEADER DOWN SOLENOID ELECTRICAL POWER SYSTEM - Component
Y20 HEADER HEIGHT CONTROL COMPENSATION ELECTRICAL POWER SYSTEM - Component
VALVE SOLENOID diagram frame 06 (A.30.A-C.20.F.06)
Y21 REEL SYNCHRONIZATION SOLENOID ELECTRICAL POWER SYSTEM - Component
Y22 POWERED REAR AXLE SOLENOID ELECTRICAL POWER SYSTEM - Component
Y23 PRE-HEATING FUEL PUMP SOLENOID ELECTRICAL POWER SYSTEM - Component
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ELECTRICAL POWER SYSTEM - Component diagram frame 01

(A.30.A - C.20.F.01)
CS540, CS640, CS520, CS660
IN-LINE HARNESS CONNECTOR (MAIN POWER SUPPLY)
CONNECTOR X2
IN-LINE HARNESS CONNECTOR (MAIN POWER SUPPLY)
POSITION WIRE NUMBER CIRCUIT REFERENCE
1 005 (RD) B(+)
NOTE: For the wiring colour code refer to Wiring General Information.
ZVE0020A 1
ZVE0116A 2
JUNCTION BOX, CAB FLOOR
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A POST MODULE (A25)
CONNECTOR X4
A POST MODULE (A25)
1 008 (GE) ALTERNATOR SIGNAL (D+)
2 106 (GN) CAN LOW SIGNAL
3 107 (GE) CAN HIGH SIGNAL
4 113 (ZW) GROUND
5 -
6 110 (OR) IGNITION B(+)
7 033 (GE) RELAY K-4 GROUND
9 039 (GE) ENGINE OIL PRESSURE LIGHT
10 038 (GE) ENGINE OIL AND COOLANT TEMPERATURE LIGHT
11 036 (GE) LADDER PROTECTION LIGHT
12 120 (WT) UNLOADING TUBE OPEN/CLOSE LIGHT
13 185 (GE) SPREADER PLATES LIGHT
14 186 (GE) SPREADER PLATES LIGHT
15 079 (GE) STRAW WALKER PROTECTION LIGHT
16 306 (GE) THRESHING MECHANISM PRESSURE LIGHT (LOW)
17 402 (GE) GRAIN TANK LEVEL INDICATOR LIGHT
18 129 (GE) GRAIN TANK LEVEL 1 SWITCH SIGNAL
20 307 (GE) THRESHING MECHANISM PRESSURE LIGHT (OK)
21 137 (GE) PARKING BRAKE LIGHT
22 192 (GE) BRAKE OIL LEVEL AND BRAKE LINING WARNING LIGHT
23 414 (GE) HYDROSTATIC OIL TEMPERATURE LIGHT
24 133 (GE) ENGINE AIR FILTER RESTRICTION LIGHT
25 134 (GE) HYDROSTATIC OIL PRESSURE LIGHT
26 098 (GE) FUEL LEVEL SENSOR SIGNAL
27 097 (GE) ENGINE TEMPERATURE SENSOR SIGNAL
28 -
29 218 (PU) RH SIDE INDICATOR LIGHT
30 217 (PU) LH SIDE INDICATOR LIGHT
31 -
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ZVE0021A 3
ZVE0126A 4
RIGHT HAND SIDE CAB ROOF
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IN-LINE HARNESS CONNECTOR
CONNECTOR X5
1 184 (GR) SPREADER PLATES SWITCH SIGNAL
2 183 (GE) SPREADER PLATES SWITCH SIGNAL
3 060 (GR) DRUM VARIATOR SWITCH SIGNAL
4 059 (WT) DRUM VARIATOR SWITCH SIGNAL
5 004 (BL) RADIO GROUND
6 008 (GE) ALTERNATOR SIGNAL (D+)
7 014 (WT) SWITCHED START SIGNAL
8 -
9 -
10 039 (GE) ENGINE OIL PRESSURE SENSOR
11 038 (GE) ENGINE OIL AND COOLANT TEMPERATURE SWITCHES
12 414 (GE) HYDROSTATIC OIL TEMPERATURE SWITCH
13 185 (GE) SPREADER PLATES POSITION SENSOR SIGNAL
15 077 (GE) SWATH PLATE POSITION SENSOR SIGNAL
16 112 (ZW) SWATH PLATE POSITION SENSOR GROUND
17 112 (ZW) STRAW CHOPPER POSITION SENSOR GROUND
18 075 (GE) STRAW CHOPPER POSITION SENSOR SIGNAL
19 079 (GE) STRAW WALKER PROTECTION SWITCH SIGNAL
21 133 (GE) ENGINE AIR FILTER RESTRICTION SWITCH SIGNAL
22 134 (GE) HYDROSTATIC OIL PRESSURE SWITCH
23 097 (GE) ENGINE TEMPERATURE SENSOR LIGHT
24 - REVOLVING FLASHING LIGHT (STRAW HOOD) SIGNAL
25 259 (WT) REEL SYNCHRONIZATION SOLENOID
26 278 (WT) RELAY K–35 ACTIVATION
27 230 (PU) LH SIDE REAR OPERATING LIGHT SIGNAL
28 405 (WT) RELAY K-51 ACTIVATION
29 296 (GE) AIR CONDITIONING HIGH PRESSURE SWITCH SIGNAL
30 297 (GE) AIR CONDITIONING PRESSURE SENSORS GROUND CIRCUIT
31 026 (BL) REEL SYNCHRONIZATION SOLENOID
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ZVE0001A 5
ZVE0118A 6
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12 V CONNECTOR
CONNECTOR X9
12 V CONNECTOR
1 056 (RD) B(+)
1 016 (ZW) GROUND
ZVE0319A 7
ZVE0129A 8
RIGHT HAND SIDE MODULE
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ENGINE STOP SOLENOID
CONNECTOR X14
ENGINE STOP SOLENOID (Y3)
A 028 (WT) RELAY K-3 IGNITION B(+)
B 030 (WT) RELAY K-1 ACTUATION
C 029 (ZW) GROUND
ZVE0023A 9
ZVE0131A 10
LEFT HAND SIDE OF ENGINE
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IN-LINE HARNESS CONNECTOR (GROUND)
CONNECTOR X25
1 004 (BL) RADIO GROUND
2 -
ZVE0029A 11
ZVE0144A 12
BEHIND HYDROSTATIC OIL RESERVOIR
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12 V PLUG
CONNECTOR X80
12 V PLUG
1 128 (ZW) GROUND
ZVE0320A 13
ZVE0182A 14
CAB FLOOR, UNDER OPERATOR’S SEAT
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CIGARETTE LIGHTER
CONNECTOR X87
CIGARETTE LIGHTER
1 056 (RD) B(+)
1 016 (ZW) GROUND
ZVE0327A 15
ZVE0326A 16
RIGHT HAND MODULE
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FUSE PRINTED CIRCUIT
CONNECTOR X112
1 405 (WT) RELAY K-51 ACTUATION
3 218 (PU) LH SIDE INDICATOR LIGHTS SIGNAL
4 218 (PU) LH SIDE FRONT INDICATOR LIGHTS SIGNAL
5 218 (PU) LH SIDE REAR INDICATOR LIGHTS AND A-POST SIGNAL
8 042 (RD) B(+)
10 -
13 160 (PK) GROUND
14 160 (BL) GROUND
16 -
17 -
18 -
19 -
20 -
21 -
22 -
23 -
ZVE0071A 17
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ZVE0193A 18
RIGHT HAND SIDE CAB
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CONNECTOR X113
1 209 (PU) DIP BEAM SWITCH SIGNAL
2 031 (WT) SWITCHED IGNITION B(+)
3 206 (PU) RELAY K-26 ACTUATION
5 090 (WT) SELF-LEVELLING ACTUATOR SIGNAL
7 056 (RD) B(+)
8 -
11 208 (PK) RELAY K-26 ACTUATION
15 202 (PU) RELAY K–26 ACTUATION
16 -
17 -
18 -
19 -
20 -
21 -
22 -
23 -
ZVE0072A 19
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ZVE0194A 20
RIGHT HAND SIDE CAB
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CONNECTOR X116
1 005 (RD) B(+)
VFIL04CS0141A0A 21
VFIL04CS0140A0A 22
RIGHT HAND SIDE CAB
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CONNECTOR X117
1 257 (RD) B(+)
VFIL04CS0136A0A 23
VFIL04CS0140A0B 24
RIGHT HAND SIDE CAB
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CONNECTOR X118
1 257 (RD) B(+)
VFIL04CS0136A0B 25
VFIL04CS0140A0C 26
RIGHT HAND SIDE CAB
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CONNECTOR X119
1 069 (ZW) GROUND
VFIL04CS0136A0C 27
VFIL04CS0140A0D 28
RIGHT HAND SIDE CAB
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CCM-MODULE (A8)
CONNECTOR X142
CCM-MODULE (A8)
1 161 (PK) REFERENCE VOLTAGE (SENSORS)
2 160 (BL) GROUND (SENSORS)
4 088 (BL) GROUND (SENSORS)
5 130 (GE) HEADER PRESSURE SENSOR SIGNAL
6 304 (GR) ROTARY DUST SCREEN BRUSH RELAY K53
8 305 (WT) ROTARY DUST SCREEN BRUSH RELAY K53.1
9 085 (ZW) GROUND
10 085 (ZW) GROUND
11 151 (GE) RH SIDE ADDITIONAL LATERAL FLOAT SENSOR SIGNAL
12 159 (GE) ENGINE SIGNAL
13 099 (GE) GROUNDSPEED SENSOR SIGNAL
14 103 (GE) DRUMSPEED SENSOR SIGNAL
15 084 (WT) SELF–LEVELLING SWITCH SIGNAL
16 128 (ZW) GROUND
17 605 (WT) RELAY K–52 GROUND
18 161 (PK) LATERAL FLOAT SENSORS REFERENCE VOLTAGE
19 089 (BL) SELF-LEVELLING ACTUATOR SIGNAL
20 089 (BL) SELF–LEVELLING ACTUATOR SIGNAL
21 150 (GE) LH SIDE ADDITIONAL LATERAL FLOAT SENSOR SIGNAL
22 101 (GE) FANSPEED SENSOR SIGNAL
23 172 GE) STUBBLE HEIGHT SETTING SIGNAL
24 265 (GE) HEADER HEIGHT MODE SIGNAL
25 173 (GE) COMPENSATION ADJUSTMENT SETTING SIGNAL
26 606 (WT) RELAY K–52 ACTIVATION
28 -
31 032 (GE) INCLINOMETER SIGNAL
32 087 (GE) SELF-LEVELLING ACTUATOR POTENTIOMETER SIGNAL
33 -
34 -
35 -
36 165 (GE) HEADER HEIGHT SENSOR SIGNAL
37 147 (GE) LH SIDE LATERAL FLOAT SENSOR SIGNAL
38 148 (GE) RH SIDE LATERAL FLOAT SENSOR SIGNAL
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ZVE0014A 29
ZVE0209A 30
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CONNECTOR X161
2 183 (GE) SPREADER PLATES SWITCH SIGNAL
3 -
4 -
A 609 (GE) HEADER ENGAGEMENT SIGNAL
B 014 (WT) SWITCHED START SIGNAL
C 058 (WT) THRESHING MECHANISM SUPPLY B(+)
D 167 (WT) AUTOMATIC HEADER HEIGHT CONTROL SWITCH SIGNAL
E 610 (WT) IGNITION B(+)
F 064 (WT) HEADER ENGAGEMENT SOLENOID SIGNAL
G 070 (GR) REEL VARITOR SWITCH (SLOW) SIGNAL
H 095 (WT) REVERSING MECHANISM SOLENOID SIGNAL
J 060 (GR) DRUM VARIATOR SWITCH SIGNAL
K 021 (WT) REVERSE DRIVE BUZZER
L 138 (GR) LATERAL FLOAT SWITCH SIGNAL (LH SIDE DOWN)
M 094 (GR) REVERSING MECHANISM SOLENOID SIGNAL (SLOW FORWARD)
N 014 (WT) SWITCHED START SIGNAL
P 021 (WT) REVERSE DRIVE BUZZER
R 265 (GE) HEADER HEIGHT MODE SIGNAL
S 055 (WT) IGNITION B(+) ROAD SAFETY
T 266 (WT) REEL SPEED SYNCHRONIZATION SWITCH
U 084 (WT) SELF-LEVELLING SWITCH SIGNAL
V -
W 602 (WT) LADDER PROTECTION RELAY CIRCUIT
AA 118 (OR) IGNITION B(+)
BB 613 (WT) SAFETY ON THE ROAD SWITCH SIGNAL
CC -
DD -
EE -
FF -
GG -
HH -
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ZVE0018A 31
ZVE0223A 32
RIGHT HAND SIDE CAB FLOOR
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CONNECTOR X190
1 113 (ZW) RELAY K-2 ACTIVATION
2 -
3 -
4 114 (BL) LATERAL FLOAT SOLENOIDS GROUND
5 088 (BL) SENSOR GROUND
8 -
9 -
10 125 (GE) RELAY K-53 AND K-53.1 ACTIVATION
11 - RELAY K-3 ACTUATION IGNITION B(+)
12 028 (WT) RELAY K-3 IGNITION B(+)
15 -
ZVE0103A 33
ZVE0239A 34
RIGHT HAND SIDE CAB
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CONNECTOR X192
1 056 (RD) B(+)
VFIL04CS0136A0E 35
VFIL04CS0140A0F 36
RIGHT HAND SIDE CAB
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MAIN BATTERY SWITCH
CONNECTOR S1
MAIN BATTERY SWITCH
1 002 (ZW) GROUND
1 003 (ZW) GROUND
VFIL04CS0136A0L 37
VFIL04CS0152A0A 38
MID LEFT HAND SIDE
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MULTI-FUNCTION HANDLE NEUTRAL SWITCH
CONNECTOR S2
MULTI-FUNCTION HANDLE NEUTRAL SWITCH
1 014 (WT) MULTI-FUNCTION HANDLE NEUTRAL SWITCH SIGNAL
ZVE0317A 39
VFIL04CS0127A0A 40
MULTIFUNCTION HANDLE
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KEYSTART SWITCH
CONNECTOR S3
KEYSTART SWITCH
1 031 (WT) SWITCHED IGNITION B(+)
1 014 (WT) SWITCHED START SIGNAL
1 015 (RD) B(+)
ZVE0318A 41
ZVE0321A 42
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(A.30.A - C.20.F.02)
CS540, CS640, CS520, CS660
PRE-HEATING FUEL PUMP (Y23)
CONNECTOR X75
PRE-HEATING FUEL PUMP (Y23)
A 277 (WT) PRE-HEATING FUEL PUMP SIGNAL
B 029 (ZW) GROUND
VFIL04CS0138A0A 1
VFIL04CS0110A0A 2
ENGINE AIR INTAKE MANIFOLD
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COLD START PRE-HEATING SWITCH (S66)
CONNECTOR S66
COLD START PRE-HEATING SWITCH
1 -
2A -
2B 056 (RD) B(+)
4 -
5A -
5B -
6 -
7 -
8 -
9 -
10 -
ZVE0252A 3
ZVE0340A 4
RIGHT HAND SIDE CAB
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(A.30.A - C.20.F.03)
CS540, CS640, CS520, CS660
DIAGNOSTIC PLUG
CONNECTOR X35
DIAGNOSTIC PLUG
A 068 (ZW) GROUND
B 618 (RD) B(+)
C 107 (GE) CAN HIGH SIGNAL
D 106 (GN) CAN LOW SIGNAL
E -
F 108 (GN) RS 232 SIGNAL
G 109 (GE) RS 232 SIGNAL
H -
J -
VFIL04CS0132A0A 1
ZVE0153A 2
BELOW FUSE PRINTED CIRCUIT, RIGHT HAND CAB
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CONNECTOR X111
3 086 (PK) REFERENCE VOLTAGE
7 605 (WT) RELAY K-52 GROUND
8 -
15 -
16 -
17 -
18 -
19 -
20 -
21 -
22 -
23 -
ZVE0070A 3
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ZVE0192A 4
RIGHT HAND SIDE CAB
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CONNECTOR X114
1 -
2 -
7 177 (BL) STRAW WALKER GRAIN LOSS SENSOR GROUND
9 -
11 307 (GE) THRESHING MECHANISM PRESSURE LIGHT (OK) SIGNAL
12 111 (RD) B(+)
13 -
14 -
15 -
16 -
17 -
18 -
19 -
20 -
21 -
22 -
23 -
ZVE0073A 5
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ZVE0195A 6
RIGHT HAND SIDE CAB
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CCM-MODULE (A8)
CONNECTOR X141
CCM-MODULE (A8)
1 266 (WT) REEL SPEED SYNCHRONIZATION SWITCH
2 153 (WT) HEADER UP SLOW SWITCH SIGNAL
3 142 (WT) LATERAL FLOAT SOLENOID SIGNAL (RH SIDE UP)
4 -
5 156 (GR) HEADER HEIGHT CONTROL (DOWN) SOLENOID
7 163 (WT) HEADER HEIGHT CONTROL COMPENSATION SOLENOID
8 168 (GE) HEADER HEIGHT CONTROL LIGHT SIGNAL (RED)
9 169 (GE) HEADER HEIGHT CONTROL LIGHT SIGNAL (GREEN)
10 138 (GR) LATERAL FLOAT SWITCH SIGNAL INPUT (LH SIDE DOWN)
11 139 (WT) LATERAL FLOAT SWITCH SIGNAL INPUT (RH SIDE DOWN)
12 610 (WT) IGNITION B(+)
13 125 (GE) RELAY K-53 AND K-53.1 ACTIVATION
14 141 (GR) LATERAL FLOAT SOLENOID SIGNAL (LH SIDE UP)
15 155 (WT) HEADER HEIGHT CONTROL (UP) SOLENOID
16 167 (ZW) AUTOMATIC HEADER HEIGHT CONTROL SWITCH SIGNAL INPUT
17 109 (GE) RS232 SIGNAL
18 -
19 609 (GE) HEADER ENGAGEMENT SIGNAL
21 092 (GR) SELF-LEVELLING OVERRIDE SWITCH SIGNAL (LH SIDE)
22 071 (WT) REEL VARIATOR SWITCH (FAST) SIGNAL
23 070 (GR) REEL VARIATOR SWITCH (SLOW) SIGNAL
24 112 (ZW) GROUND
25 082 (GE) STRAW WALKER SENSOR SIGNAL
26 123 (GE) RETURN ELEVATOR SENSOR SIGNAL
27 108 (GN) RS232 SIGNAL
28 080 (GE) REEL SPEED SENSOR SIGNAL
29 -
30 154 (GR) HEADER DOWN SLOW SWITCH SIGNAL
31 111 (RD) B(+)
33 -
36 420 (GE) ROTARY SEPARATOR SENSOR SIGNAL
37 093 (WT) SELF–LEVELLING OVERRIDE SWITCH SIGNAL (RH SIDE)
39 -
40 191 (WT) HEADER UP/DOWN FAST SWITCH SIGNAL
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ZVE0013A 7
ZVE0208A 8
A POST MODULE (A25)

CCM-MODULE (A8)

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(A.30.A - C.20.F.04)
CS540, CS640, CS520, CS660
CONNECTOR X10
1 062 (GR) FAN VARIATOR SWITCH SIGNAL
2 061 (WT) FAN VARIATOR SWITCH SIGNAL
3 206 (PU) ADDITIONAL RH PARK LIGHT SIGNAL
4 098 (GE) FUEL LEVEL SENSOR SIGNAL
5 021 (WT) REVERSE DRIVE BUZZER
6 -
8 178 (GE) STRAW WALKER GRAIN LOSS SENSOR SIGNAL
11 177 (BL) SIEVES GRAIN LOSS SENSOR GROUND
12 182 (GE) SIEVES GRAIN LOSS SENSOR SIGNAL
13 218 (PU) LH SIDE REAR INDICATOR LIGHTS SIGNAL
14 217 (PU) RH SIDE REAR INDICATOR LIGHTS SIGNAL
15 194 (PU) BRAKE LIGHT SWITCH SIGNAL
16 202 (PU) LH SIDE REAR PARK LIGHTS SIGNAL
17 205 (PU) RH SIDE REAR PARK LIGHTS SIGNAL
18 -
19 036 (GE) LADDER PROTECTION SWITCH
20 -
21 128 (ZW) GROUND
22 052 (WT) ROTARY DUST SCREEN BRUSH (FAST) SIGNAL
23 -
24 -
25 608 (GR) ROTARY DUST SCREEN BRUSH (SLOW) SIGNAL
26 230 (PU) RH SIDE REAR OPERATING LIGHT SIGNAL
27 -
28 602 (GE) LADDER PROTECTION RELAY CIRCUIT
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ZVE0002A 1
ZVE0119A 2
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ENGINE PROTECTION RESET + KILL STOP SWITCH (S9)
CONNECTOR S9
ENGINE PROTECTION RESET + KILL STOP SWITCH
1 033 (GE) RELAY K-4 ACTIVATION
2A
2B 016 (ZW) GROUND
4
5A
5B
6
7
8
9
10
ZVE0253A 3
ZVE0339A 4
RIGHT HAND SIDE CAB
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A POST MODULE (A25)



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(A.30.A - C.20.F.05)
CS540, CS640, CS520, CS660
REVERSE DRIVE BUZZER
CONNECTOR X11
1 128 (ZW) GROUND
2 021 (WT) REVERSE DRIVE BUZZER SIGNAL
ZVE0025A 1
ZVE0130A 2
UNDER REAR OPERATORS PLATFORM
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CONNECTOR X12
A 046 (GR) REEL DOWN SIGNAL
B 047 (WT) REEL UP SIGNAL
C 048 (WT) UNLOADING TUBE OPEN SIGNAL
D 049 (GR) UNLOADING TUBE CLOSE SIGNAL
E 094 (GR) REVERSING MECHANISM SOLENOID SIGNAL (SLOW FORWARD)
F 095 (WT) REVERSING MECHANISM SOLENOID SIGNAL
G 156 (GR) HEADER HEIGHT CONTROL (DOWN) SOLENOID
H 155 (WT) HEADER HEIGHT CONTROL (UP) SOLENOID
J 112 (ZW) REVERSING MECHANISM SOLENOID GROUND
K 112 (ZW) REVERSING MECHANISM SOLENOID GROUND
L 157 (BL) HEADER HEIGHT CONTROL (UP) SOLENOID
M 157 (BL) HEADER HEIGHT CONTROL (DOWN) SOLENOID
N 115 (WT) REEL FORWARD SIGNAL
O 116 (GR) REEL REARWARD SIGNAL
P 112 (ZW) REEL FORWARD SOLENOID GROUND
Q 112 (ZW) REEL REARWARD SOLENOID GROUND
R 112 (ZW) REEL DOWN SOLENOID GROUND
S 112 (ZW) REEL UP SOLENOID GROUND
T 112 (ZW) UNLOADING TUBE OPEN SOLENOID GROUND
U 112 (ZW) UNLOADING TUBE CLOSE SOLENOID GROUND
V 285 (WT) RELAY K-27 ACTIVATION
W -
X -
ZVE0003A 3
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ZVE0120A 4
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PRINTED CIRCUIT (REAR LIGHTS)
CONNECTOR X16
1 128 (ZW) GROUND
2 128 (ZW) GROUND
3 128 (ZW) GROUND
4 -
5 128 (ZW) GROUND
6 128 (ZW) GROUND
7 -
8 128 (ZW) GROUND
ZVE0112A 5
ZVE0133A 6
MID RIGHT HAND SIDE
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UNLOADING TUBE ENGAGEMENT AND REEL FWD/RWD SWITCHES (S33, S4, S6)
CONNECTOR X36
UNLOADING TUBE ENGAGEMENT AND REEL FWD/RWD SWITCHES (S33, S4, S6)
1 116 (GR) REEL REARWARD SIGNAL
2 115 (WT) REEL FORWARD SIGNAL
4 055 (WT) UNLOADING TUBE SWITCH SUPPLY ROAD SAFETY B(+)
5 121 (WT) UNLOADING TUBE SWITCH SIGNAL
6 -
ZVE0038A 7
ZVE0154A 8
FRONT, UNDER CAB FLOOR
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PRINTED CIRCUIT (RIGHT HAND MODULE)
CONNECTOR X122
1 048 (WT) UNLOADING TUBE OPEN SIGNAL
2 047 (WT) REEL UP SIGNAL
3 046 (GR) REEL DOWN SIGNAL
4 611 (BL) MANUAL HEADER HEIGHT CONTROL SIGNAL
5 157 (BL) HEADER HEIGHT CONTROL (UP/DOWN) SOLENOID GROUND
6 600 (GR) REEL SPEED (FAST) RELAY K-12 SIGNAL
7 054 (WT) THRESHING ENGAGEMENT GROUND
8 045 (ZW) GROUND
10 IGNITION B(+) ROAD SAFETY
11 055 (WT) IGNITION B(+) ROAD SAFETY
14 049 (GR) UNLOADING TUBE CLOSE SIGNAL
15 139 (WT) LATERAL FLOAT SWITCH SIGNAL (RH SIDE DOWN)
16 138 (GR) LATERAL FLOAT SWITCH SIGNAL (LH SIDE DOWN)
22 -
23 -
25 058 (WT) THRESHING MECHANISM SUPPLY B(+)
26 -
ZVE0076A 9
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ZVE0198A 10
RIGHT HAND MODULE
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CONNECTOR X123
1 (BR) REEL DOWN SWITCH SIGNAL
2 (GN) HEADER UP SLOW SWITCH SIGNAL
3 (GE) HEADER DOWN SLOW SWITCH SIGNAL
4 (BR/GN) IGNITION B(+)
5 -
6 (RD/WT) IGNITION B(+)
7 (BL) REEL VARIATOR SWITCH (FAST) SIGNAL
8 (WT/GR) IGNITION B(+) ROAD SAFETY
9 (RD) REEL VARIATOR SWITCH (SLOW) SIGNAL
10 (GN/WT) REVERSE MECHANISM SWITCH SIGNAL
11 -
12 (BR/WT) IGNITION B(+)
13 -
14 (BR/GE) HEADER UP FAST SWITCH SIGNAL
15 (BL/WT) HEADER DOWN FAST SWITCH SIGNAL
18 (PK/WT) UNLOADING TUBE CLOSE SWITCH SIGNAL
19 (PU) UNLOADING TUBE OPEN SWITCH SIGNAL
20 (WT) REEL UP SWITCH SIGNAL
21 -
22 167 (ZW/WT) AUTOMATIC HEADER HEIGHT CONTROL SWITCH SIGNAL
23 -
24 -
25 (ZW) IGNITION B(+) ROAD SAFETY
ZVE0278A 11
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ZVE0199A 12
RIGHT HAND MODULE
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CONNECTOR X159
A 115 (WT) REEL FORWARD SIGNAL
B -
C 116 (GR) REEL REARWARD SIGNAL
D 073 (WT) REEL VARIATOR MOTOR (FAST) SIGNAL
E 072 (GR) REEL VARIATOR MOTOR (SLOW) SIGNAL
F 020 (OR) IGNITION B(+)
G -
H 055 (WT) IGNITION B(+) ROAD SAFETY
J 194 (PU) BRAKE LIGHT SWITCH SIGNAL
K 128 (ZW) GROUND
L 420 (GE) REEL SPEED SENSOR SIGNAL
M 112 (ZW) REEL SPEED SENSOR GROUND
N 161 (PK) LATERAL FLOAT SENSORS REFERENCE VOLTAGE
P 218 (PU) LH SIDE FRONT INDICATOR LIGHTS SIGNAL
R 217 (PU) RH SIDE FRONT INDICATOR LIGHTS SIGNAL
S 110 (OR) IGNITION B(+)
T 161 (PK) LATERAL FLOAT SENSORS REFERENCE VOLTAGE
U 202 (PU) LH SIDE FRONT PARK LIGHTS AND GRAIN HEAD ILLUMINATION
SIGNAL
V 205 (PU) RH SIDE FRONT PARK LIGHTS SIGNAL
W 022 (PU) DIP BEAM SWITCH SIGNAL LH SIDE
X 022 (PU) DIP BEAM SWITCH SIGNAL RH SIDE
ZVE0016A 13
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ZVE0125A 14
JUNCTION BOX - CAB FLOOR
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CONNECTOR X160
1 157 (BL) HEADER HEIGHT CONTROL (UP) SOLENOID GROUND
2 661 (BL) MANUAL HEADER HEIGHT CONTROL SIGNAL
4 043 (WT) REEL SPEED (SLOW) RELAY K11 SIGNAL
6 046 (GR) REEL DOWN SIGNAL
8 047 (WT) REEL UP SIGNAL
9 506 (WT) RIGHT HAND SIDE VERTICAL KNIFE SWITCH SIGNAL
12 049 (GR) UNLOADING TUBE CLOSE SIGNAL
14 048 (WT) UNLOADING TUBE OPEN SIGNAL
16 507 (WT) LEFT HAND SIDE VERTICAL KNIFE SWITCH SIGNAL
17 600 (GR) REEL SPEED (FAST) RELAY K12 SIGNAL
23 157 (BL) HEADER HEIGHT CONTROL (DOWN) SOLENOID GROUND
24 059 (WT) DRUM VARIATOR SWITCH SIGNAL
27 088 (BL) GROUND
28 172 (GE) STUBBLE HEIGHT SETTING SIGNAL
32 -
33 -
34 -
35 -
36 -
37 -
38 -
39 -
40 -
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41 -
42 -
43 -
44 -
45 -
46 -
47 -
48 -
ZVE0017A 15
ZVE0225A 16
RIGHT HAND MODULE
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CONNECTOR X162
A 073 (WT) REEL VARIATOR MOTOR (SLOW) SIGNAL
B 072 (GR) REEL VARIATOR MOTOR (FAST) SIGNAL
C 016 (ZW) GROUND
D 062 (GR) FAN VARIATOR SWITCH SIGNAL
E 061 (WT) FAN VARIATOR SWITCH SIGNAL
F 017 (OR) IGNITION B(+)
G -
H -
I -
J -
1 508 (WT) GROUND
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
15 -
16 -
17 -
18 -
19 -
ZVE0226A 17
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ZVE0224A 18
RIGHT HAND MODULE
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REEL FORWARD SWITCH (S4)
CONNECTOR X36 (S4)

UNLOADING TUBE ENGAGEMENT AND REEL FWD/RWD SWITCHES
6 -
ZVE0038A 19
VFIL04CS0116A0A 20
CAB FLOOR
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REVERSE DRIVE BUZZER SWITCH (S5)
CONNECTOR S5
REVERSE DRIVE BUZZER SWITCH
1 021 (WT) REVERSE DRIVE BUZZER / CCM SIGNAL
VFIL04CS0126A0A 21
VFIL04CS0142A0A 22
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REEL REARWARD SWITCH (S6)
CONNECTOR X36 (S6)

UNLOADING TUBE ENGAGEMENT AND REEL FWD/RWD SWITCHES
6 -
ZVE0038A 23
VFIL04CS0116A0B 24
CAB FLOOR
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REEL DOWN SWITCH (S11)
CONNECTOR X123 (S11)

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 25
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VFIL04CS0115A0A 26
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REEL UP SWITCH (S12)

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 27
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VFIL04CS0115A0B 28
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UNLOADING TUBE OPEN SWITCH (S13)

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 29
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VFIL04CS0115A0C 30
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UNLOADING TUBE CLOSE SWITCH (S14)

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 31
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VFIL04CS0115A0D 32
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REEL DOWN SOLENOID (Y4)
CONNECTOR Y4
REEL DOWN SOLENOID
1 157 (BL) SOLENOID CIRCUIT
2 155 (WT) SOLENOID CIRCUIT
ZVE0357A 33
ZVE0287A 34
CAB LEFT OPERATOR’S PLATFORM
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REEL UP SOLENOID (Y5)
CONNECTOR Y5
REEL UP SOLENOID
ZVE0358A 35
ZVE0286A 36
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UNLOADING TUBE OPEN SOLENOID (Y6)
CONNECTOR Y6
UNLOADING TUBE OPEN SOLENOID
ZVE0359A 37
ZVE0289A 38
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UNLOADING TUBE OPEN SOLENOID (Y7)
CONNECTOR Y7
UNLOADING TUBE CLOSE SOLENOID
ZVE0360A 39
ZVE0288A 40
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REEL FORWARD SOLENOID (Y13)
CONNECTOR Y13
REEL FORWARD SOLENOID
ZVE0363A 41
ZVE0285A 42
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REEL REARWARD SOLENOID (Y14)
CONNECTOR Y14
REEL REARWARD SOLENOID
ZVE0364A 43
ZVE0284A 44
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USE PRINTED CIRCUIT
X111 USE PRINTED CIRCUIT ELECTRICAL POWER SYSTEM - Component

CCM-MODULE (A8)

CCM-MODULE (A8)


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(A.30.A - C.20.F.06)
CS540, CS640, CS520, CS660
CONNECTOR X8
IN-LINE HARNESS CONNECTOR (HEADER SOLENOIDS Y18/Y19)
1 157 (BL) HEADER HEIGHT CONTROL (DOWN) SOLENOID
3 157 (BL) HEADER HEIGHT CONTROL (UP) SOLENOID
VFIL04CS0131A0A 1
VFIL04CS0107A0A 2
BEHIND JUNCTION BOX, CAB FLOOR
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CONNECTOR X26
1 123 (GE) RETURN ELEVATOR SENSOR SIGNAL
2 112 (ZW) RETURN ELEVATOR SENSOR GROUND
3 -
6 163 (WT) HEADER HEIGHT CONTROL COMPENSATION SOLENOID
7 112 (ZW) HEADER HEIGHT CONTROL COMPENSATION SOLENOID GROUND
8 508 (WT) GROUND
9 192 (GE) BRAKE LINING WARNING SWITCH CIRCUIT
11 112 (ZW) GROUNDSPEED SENSOR GROUND
13 112 (ZW) FANSPEED SENSOR GROUND
15 112 (ZW) DRUMSPEED SENSOR GROUND
17 112 (ZW) STRAW WALKER SENSOR GROUND
19 112 (ZW) REEL SPEED SENSOR GROUND
20 -
21 112 (ZW) HEADER ENGAGEMENT SOLENOID GROUND
22 058 (WT) THRESHING MECHANISM PRESSURE SWITCH SUPPLY B(+)
23 064 (WT) HEADER ENGAGEMENT SOLENOID SIGNAL
24 306 (GE) THRESHING MECHANISM PRESSURE SWITCH SIGNAL (LOW)
25 307 (GE) THRESHING MECHANISM PRESSURE SWITCH SIGNAL (OK)
26 612 (WT) UNLOADING TUBE ENGAGEMENT SOLENOID SIGNAL
27 112 (ZW) UNLOADING TUBE ENGAGEMENT SOLENOID GROUND
28 506 (WT) RH SIDE VERTICAL KNIFE SWITCH SIGNAL
29 507 (WT) LH SIDE VERTICAL KNIFE SWITCH SIGNAL
31 308 (WT) THRESHING MECHANISM ENGAGEMENT SOLENOID SIGNAL
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ZVE0007A 3
ZVE0121A 4
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CONNECTOR X38
1 192 (GE) BRAKE WARNING SIGNAL
2 122 (ZW) GROUND SPEED SENSOR GROUND
3 099 (GE) GROUND SPEED SENSOR SIGNAL
4 130 (GE) HEADER PRESSURE SENSOR SIGNAL
5 088 (BL) GROUND
6 086 (PK) HEADER PRESSURE SENSOR REFERENCE VOLTAGE
7 163 (WT) COMPENSATION VALVE HEADER HEIGHT CONTROL SOLENOID
SIGNAL
8 112 (ZW) COMPENSATION VALVE HEADER HEIGHT CONTROL SOLENOID
GROUND
VFIL04CS0133A0A 5
VFIL04CS0108A0A 6
LEFT HAND SIDE, BEHIND FRONT WHEEL
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CONNECTOR X40
A 055 (WT) IGNITION B(+) ROAD SAFETY
B -
C 120 (WT) UNLOADING TUBE PROTECTION SWITCH SIGNAL
D -
E -
F 129 (GE) GRAIN TANK LEVEL 1 SWITCH SIGNAL
G -
H 027 (OR) IGNITION B(+)
J 027 (OR) IGNITION B(+)
K 160 (BL) HEADER HEIGHT SENSOR GROUND
L 165 (GE) HEADER HEIGHT SENSOR SIGNAL
M 161 (PK) HEADER HEIGHT SENSOR REFERENCE VOLTAGE
N 239 (WT) WASHER PUMP SIGNAL
P -
R 142 (WT) LATERAL FLOAT SOLENOID SIGNAL (LH SIDE UP)
S 114 (BL) LATERAL FLOAT SOLENOID GROUND (RH SIDE UP)
T 114 (BL) LATERAL FLOAT SOLENOID GROUND (LH SIDE UP)
U 283 (ZW) GROUND
V 019 (GE) GRAIN TANK LEVEL 2 SWITCH SIGNAL
W 141 (GR) LATERAL FLOAT SOLENOID SIGNAL (RH SIDE UP)
X -
ZVE0009A 7
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ZVE0122A 8
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CONNECTOR X48
1 141 (GR) LATERAL FLOAT SOLENOID SIGNAL (RH SIDE UP)
2 142 (WT) LATERAL FLOAT SOLENOID SIGNAL (LH SIDE UP)
3 114 (BL) LATERAL FLOAT SOLENOID GROUND (RH SIDE UP)
4 114 (BL) LATERAL FLOAT SOLENOID GROUND (LH SIDE UP)
5 -
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
15 -
16 -
17 -
18 -
19 -
ZVE0048A 9
ZVE0165A 10
LEFT HAND SIDE OF FRONT ELEVATOR
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HEADER PRESSURE SENSOR (B18)
CONNECTOR X88
HEADER PRESSURE SENSOR(B18)
A 088 (BL) GROUND
B 086 (PK) HEADER PRESSURE SENSOR REFERENCE VOLTAGE
C 130 (GE) HEADER PRESSURE SENSOR SIGNAL
ZVE0061A 11
ZVE0299A 12
ABOVE FRONT AXLE
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CONNECTOR X121
1 073 (WT) REEL VARIATOR MOTOR (FAST) SIGNAL
2 095 (WT) REVERSING MECHANISM SOLENOID SIGNAL
3 094 (GR) REVERSING MECHANISM SOLENOID SIGNAL (SLOW FORWARD)
4 602 (WT) LADDER PROTECTION RELAY CIRCUIT
6 262 (WT) THRESHING ENGAGED B(+)
10 -
11 070 (GR) REEL VARIATOR SWITCH (SLOW) SIGNAL
12 167 (WT) AUTOMATIC HEADER HEIGHT CONTROL SWITCH SIGNAL
13 265 (GE) HEADER HEIGHT MODE SWITCH SIGNAL
14 072 (GR) REEL VARIATOR MOTOR (SLOW) SIGNAL
16 -
17 -
20 -
21 610 (WT) IGNITION B(+)
22 045 (ZW) GROUND
23 057 (BL) HEADER ENGAGEMENT SWITCH GROUND
24 609 (GE) HEADER ENGAGEMENT SIGNAL
25 265 (GE) HEADER HEIGHT MODE SIGNAL
26 -
27 -
ZVE0075A 13
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ZVE0197A 14
RIGHT HAND MODULE
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LATERAL FLOTATION LEFT DOWN SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 15
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VFIL04CS0115A0G 16
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LATERAL FLOTATION RIGHT DOWN SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 17
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VFIL04CS0115A0H 18
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HEADER UP SLOW SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 19
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VFIL04CS0115A0I 20
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HEADER DOWN SLOW SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 21
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VFIL04CS0115A0J 22
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AUTOMATIC HEADER HEIGHT CONTROL SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 23
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VFIL04CS0154A0A 24
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HEADER UP FAST SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 25
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VFIL04CS0115A0K 26
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HEADER DOWN FAST SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 27
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VFIL04CS0115A0L 28
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CCM OVERRIDE SWITCH
CONNECTOR S80
CCM OVERRIDE SWITCH
1 - RELAY K19 ACTIVATION
2 - HEADER DOWN SLOW SWITCH SIGNAL
3 -
4 - RELAY K18 ACTIVATION
5 - HEADER UP SLOW SWITCH SIGNAL
6 -
7 - CCM SIGNAL
8 - HEADER SOLENOID SIGNAL
9 - GROUND
VFIL04CS0160A0A 29
RIGHT HAND MODULE
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LATERAL FLOAT SOLENOID (RIGHT DOWN)
CONNECTOR Y16
LATERAL FLOAT SOLENOID (RIGHT DOWN)
ZVE0365A 30
ZVE0240A 31
LEFT HAND SIDE OF ELEVATOR
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LATERAL FLOAT SOLENOID (LEFT DOWN)
CONNECTOR Y17
LATERAL FLOAT SOLENOID (LEFT DOWN)
CAV WIRE NUMBER CIRCUIT REFERENCE
ZVE0366A 32
ZVE0241A 33
LEFT HAND SIDE OF ELEVATOR
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HEADER HEIGHT UP SOLENOID
CONNECTOR Y18
HEADER HEIGHT UP SOLENOID
ZVE0106A 34
ZVE0290A 35
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HEADER DOWN SOLENOID
CONNECTOR Y19
HEADER DOWN SOLENOID
ZVE0367A 36
ZVE0291A 37
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HEADER HEIGHT CONTROL COMPENSATION SOLENOID
CONNECTOR Y20
HEADER HEIGHT CONTROL COMPENSATION SOLENOID
2 112 (ZW) SOLENOID CIRCUIT
3 -
4 -
ZVE0107A 38
ZVE0369A 39
ABOVE FRONT AXLE
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IN-LINE HARNESS CONNECTOR (SOLENOID VALVES)
X12 IN-LINE HARNESS CONNECTOR (SOLENOID ELECTRICAL POWER SYSTEM - Component

VALVES) diagram frame 05 (A.30.A-C.20.F.05)
X122 PRINTED CIRCUIT (RIGHT HAND MODULE) ELECTRICAL POWER SYSTEM - Component

CCM-MODULE (A8)

CCM-MODULE (A8)




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(A.30.A - C.20.F.07)
CS540, CS640, CS520, CS660
HEADER CONNECTOR
CONNECTOR X19
HEADER CONNECTOR
4 -
5 161 (PK) LH SIDE LATERAL FLOAT SENSOR REFERENCE VOLTAGE
6 160 (BL) LH SIDE LATERAL FLOAT SENSOR REFERENCE GROUND
7 420 (GE) REEL RPM
8 -
9 -
10 -
11 -
12 -
13 112 (ZW) REFERENCE GROUND
14 -
15 -
16 -
18 -
19 -
21 -
22 -
23 161 (PK) RH SIDE LATERAL FLOAT SENSOR REFERENCE VOLTAGE
24 202 (PU) GRAIN HEAD ILLUMINATION SIGNAL
25 160 (BL) RH SIDE LATERAL FLOAT SENSOR REFERENCE GROUND
27 -
28 -
29 -
30 128 (ZW) GRAIN HEAD ILLUMINATION GROUND
31 -
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ZVE0004A 1
ZVE0139A 2
LEFT RIGHT HAND SIDE OF HEADER
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HEADER HEIGHT SENSOR (R2)
CONNECTOR X39
HEADER HEIGHT SENSOR(R2)
1 160 (BL) GROUND
2 165 (GE) HEADER HEIGHT SENSOR SIGNAL
3 161 (PK) HEADER HEIGHT SENSOR REFERENCE VOLTAGE
ZVE0040A 3
ZVE0156A 4
UNDER CAB, RIGHT HAND SIDE
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HEADER HEIGHT CONTROL PRINTED CIRCUIT
CONNECTOR X52
3 -
5 -
9 088 (BL) GROUND
ZVE0171A 5
ZVE0172A 6
RIGHT HAND MODULE
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CONNECTOR X163
1 023 (PU) MAIN BEAM SWITCH SIGNAL LH SIDE
2 023 (PU) MAIN BEAM SWITCH SIGNAL RH SIDE
3 228 (PU) RH SIDE STUBBLE LIGHT SIGNAL
4 245 (WT) RH MIRROR MOTOR SIGNAL
5 248 (WT) LH MIRROR UP/DOWN MOTOR SIGNAL
6 249 (WT) LH MIRROR MOTOR SIGNAL
7 250 (WT) LH MIRROR LEFT/RIGHT MOTOR SIGNAL
8 251 (WT) RH MIRROR LEFT/RIGHT MOTOR SIGNAL
9 -
10 251 (WT) GERMAN MIRROR LEFT/RIGHT MOTOR SIGNAL
11 252 (WT) RH MIRROR UP/DOWN MOTOR SIGNAL
12 254 (WT) GERMAN MIRROR UP/DOWN MOTOR SIGNAL
14 613 (WT) SAFETY ON THE ROAD SWITCH SIGNAL
19 160 (BL) LATERAL FLOAT SENSORS GORUND
20 161 (PK) LATERAL FLOAT SENSORS REFERENCE VOLTAGE
21 228 (PU) LH SIDE STUBBLE LIGHT SIGNAL
22 128 (ZW) GROUND
23 160 (BL) LATERAL FLOAT SENSORS GROUND
24 -
25 -
26 112 (ZW) BRAKE SOLENOID GROUND
27 -
28 -
29 -
30 -
31 -
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ZVE0019A 7
ZVE0124A 8
JUNCTION BOX - CAB FLOOR
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HEADER HEIGHT MODES SELECTOR SWITCH (S48)
CONNECTOR X52 (S48)

3 -
5 -
9 088 (BL) GROUND
ZVE0171A 9
VFIL04CS0151A0A 10
RIGHT HAND MODULE
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CCM-MODULE (A8)

CCM-MODULE (A8)



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(A.30.A - C.20.F.08)
CS540, CS640, CS520, CS660
BRAKE SOLENOID (Y1)
CONNECTOR X6
BRAKE SOLENOID (Y1)
A 613 (WT) BRAKE SOLENOID SIGNAL
B 112 (ZW) BRAKE SOLENOID GROUND
ZVE0127A 1
ZVE0128A 2
UNDER THE CAB FLOOR
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LADDER SAFETY SWITCH
CONNECTOR X34
LADDER SAFETY SWITCH (S10)
A 602 (WT) LADDER PROTECTION RELAY CIRCUIT
B 036 (GE) LADDER PROTECTION WARNING LIGHT CIRCUIT
C 128 (ZW) GROUND
ZVE0036A 3
ZVE0152A 4
REAR LADDER
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THRESHING ENGAGEMENT SWITCH
CONNECTOR X89
THRESHING ENGAGEMENT SWITCH (S15)
1 054 (WT) THRESHING ENGAGEMENT CIRCUIT
2 045 (ZW) GROUND
ZVE0183A 5
ZVE0185A 6
RIGHT HAND MODULE
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CONNECTOR X115
1 -
2 -
3 217 (PU) RH SIDE INDICATOR LIGHTS SIGNAL
4 217 (PU) RH SIDE FRONT INDICATOR LIGHTS SIGNAL
5 217 (PU) RH SIDE REAR INDICATOR LIGHTS AND A-POST SIGNAL
8 306 (GE) THRESHING MECHANISM PRESSURE SWITCH SIGNAL (LOW)
9 214 (PU) INDICATOR LIGHT SIGNAL
10 276 (WT) RELAY K-25 POWER SUPPLY
11 215 (GE) HAZARD AND TRAILER INDICATOR WARNING LIGHT SIGNAL
14 - RELAY K-46 ACTUATION B(+) ROAD SAFETY
15 058 (WT) THRESHING MECHANISM SUPPLY B(+)
ZVE0074A 7
ZVE0196A 8
RIGHT HAND SIDE CAB
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PNEUMATIC SOLENOIDS (Y8/Y9/Y15)
CONNECTOR X155
PNEUMATIC SOLENOIDS(Y8/Y9/Y15)
1 612 (WT) UNLOADING TUBE ENGAGEMENT SOLENOID SIGNAL
2 112 (ZW) UNLOADING TUBE ENGAGEMENT SOLENOID GROUND
3 112 (ZW) HEADER ENGAGEMENT SOLENOID GROUND
5 308 (WT) THRESHING MECHANISM ENGAGEMENT SOLENOID SIGNAL
6 112 (ZW) THRESHING MECHANISM ENGAGEMENT SOLENOID GROUND
ZVE0090A 9
ZVE0219A 10
MID LEFT HAND SIDE
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THRESHING MECHANISM PRESSURE SWITCH
CONNECTOR X156
THRESHING MECHANISM PRESSURE SWITCH (S72)
A 058 (WT) THRESHING MECHANISM PRESSURE SWITCH SUPPLY B(+)
B 306 (GE) THRESHING MECHANISM PRESSURE SWITCH SIGNAL (LOW)
C 307 (GE) THRESHING MECHANISM PRESSURE SWITCH SIGNAL (OK)
ZVE0091A 11
ZVE0220A 12
MID LEFT HAND SIDE
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CONNECTOR X34
A 602 (WT) LADDER PROTECTION RELAY CIRCUIT
B 036 (GE) LADDER PROTECTION WARNING LIGHT CIRCUIT
C 128 (ZW) GROUND
ZVE0036A 13
VFIL04CS0119A0A 14
RIGHT HAND SIDE REAR
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SAFETY ON THE ROAD SWITCH (S31)
CONNECTOR S31
SAFETY ON THE ROAD SWITCH (S31)
1
2A
2B 118 (OR) IGNITION B(+)
3
4 613 (WT) BRAKE SOLENOID SIGNAL
5A
7 045 (ZW) GROUND
8
9
10
ZVE0266A 15
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ZVE0333A 16
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CONNECTOR X156
A 058 (WT) THRESHING MECHANISM PRESSURE SWITCH SUPPLY B(+)
B 306 (GE) THRESHING MECHANISM PRESSURE SWITCH SIGNAL (LOW)
C 307 (GE) THRESHING MECHANISM PRESSURE SWITCH SIGNAL (OK)
ZVE0091A 17
VFIL04CS0153A0A 18
MID LEFT HAND SIDE
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A POST MODULE (A25)







CCM-MODULE (A8)



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(A.30.A - C.20.F.09)
CS540, CS640, CS520, CS660
CONNECTOR X50
2 112 (ZW) GROUND
VFIL04CS0134A0A 1
VFIL04CS0148A0A 2
RIGHT HAND SIDE, BEHIND FRONT WHEEL
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HEADER ENGAGEMENT SWITCH (S16)
CONNECTOR X90
HEADER ENGAGEMENT SWITCH (S16)
1 054 (WT) HEADER ENGAGEMENT CIRCUIT
2 045 (ZW) GROUND
ZVE0184A 3
ZVE0186A 4
RIGHT HAND MODULE
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REVERSING MECHANISM SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 5
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VFIL04CS0154A0B 6
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REVERSING MECHANISM SOLENOID
CONNECTOR Y10
ZVE0361A 7
ZVE0282A 8
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CONNECTOR Y12
ZVE0362A 9
ZVE0283A 10
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CCM-MODULE (A8)

X155 PNEUMATIC SOLENOIDS (Y8/Y9/Y15) ELECTRICAL POWER SYSTEM - Component


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(A.30.A - C.20.F.10)
CS540, CS640, CS520, CS660
REEL VARIATOR MOTOR (M5)
CONNECTOR X20
REEL VARIATOR MOTOR (M5)
ZVE0140A 1
ZVE0141A 2
LEFT HAND SIDE OF HEADER
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REEL SYNCHRONIZATION SOLENOID (Y21)
CONNECTOR X21
REEL SYNCHRONIZATION SOLENOID (Y21)
ZVE0027A 3
ZVE0142A 4
LEFT HAND SIDE OF ENGINE
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ROTARY DUST SCREEN BRUSH (M14)
CONNECTOR X102
ROTARY DUST SCREEN BRUSH (M14)
1 -
ZVE0065A 5
ZVE0375A 6
ROTARY DUST SCREEN BRUSH
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IN-LINE HARNESS CONNECTOR (ROTARY DUST SCREEN BRUSH)
CONNECTOR X138
IN-LINE HARNESS CONNECTOR (ROTARY DUST SCREEN BRUSH)
ZVE0085A 7
ZVE0368A 8
RIGHT HAND SIDE, BELOW ROTARY DUST SCREEN
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CONNECTOR X194
1 600 (GR) REEL SPEED (FAST) RELAY K12 SIGNAL
3 304 (GR) ROTARY DUST SCREEN BRUSH RELAY K53
4 -
5 -
6 -
9 305 (WT) ROTARY DUST SCREEN BRUSH RELAY K53.1
ZVE0330A 9
ZVE0329A 10
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REEL VARIATOR SLOW SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 11
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VFIL04CS0115A0E 12
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REEL VARIATOR FAST SWITCH

5 -
11 -
13 -
21 -
23 -
24 -
ZVE0278A 13
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VFIL04CS0115A0F 14
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REEL SYNCHRONIZATION SWITCH
CONNECTOR S65
REEL SYNCHRONIZATION SWITCH
1
2A
2B 055 (WT) IGNITION B(+) ROAD SAFETY
3
4
5A
6 266 (WT) REEL SYNCHRONIZATION SWITCH SIGNAL
7 (ZW) GROUND
8
9
10
ZVE0258A 15
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ZVE0335A 16
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HEADER CONNECTOR


CCM-MODULE (A8)

CCM-MODULE (A8)





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(A.30.A - C.20.F.11)
CS540, CS640, CS520, CS660
UNLOADING TUBE PROTECTION SWITCH
CONNECTOR X92
UNLOADING TUBE PROTECTION SWITCH (S32)
A 120 (WT) UNLOADING TUBE PROTECTION SWITCH SIGNAL
B -
C 055 (WT) UNLOADING TUBE PROTECTION SWITCH SUPPLY ROAD SAFETY
B(+)
ZVE0062A 1
ZVE0187A 2
UNLOADING TUBE GEARBOX
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LIGHTS PRINTED CIRCUIT
CONNECTOR X127
1 120 (WT) UNLOADING TUBE PROTECTION SWITCH SIGNAL
4 -
5 230 (PU) RELAY K-32 ACTUATION ON FUSE 33
8 -
9 219 (RD) B(+)
ZVE0079A 3
ZVE0202A 4
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UNLOADING TUBE ENGAGEMENT SWITCH (S33)
CONNECTOR X36
UNLOADING TUBE ENGAGEMENT SWITCH (S33)
6 -
ZVE0038A 5
VFIL04CS0118A0A 6
CAB FLOOR
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A POST MODULE (A25)


X36 UNLOADING TUBE ENGAGEMENT AND REEL ELECTRICAL POWER SYSTEM - Component
FWD/RWD SWITCHES (S33, S4, S6) diagram frame 05 (A.30.A - C.20.F.05)

USE PRINTED CIRCUIT

X155 PNEUMATIC SOLENOIDS (Y8/Y9/Y15) ELECTRICAL POWER SYSTEM - Component





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(A.30.A - C.20.F.12)
CS540, CS640, CS520, CS660
DRUM VARIATOR MOTOR (M3)
CONNECTOR X17
DRUM VARIATOR MOTOR (M3)
1 272 (WT) DRUM VARIATOR MOTOR CIRCUIT
2 273 (GR) DRUM VARIATOR MOTOR CIRCUIT
3 -
ZVE0024A 1
ZVE0137A 2
MID LEFT HAND SIDE
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FAN VARIATOR MOTOR (M4)
CONNECTOR X18
FAN VARIATOR MOTOR (M4)
A 061 (WT) FAN VARIATOR MOTOR CIRCUIT
B 062 (GR) FAN VARIATOR MOTOR CIRCUIT
ZVE0026A 3
ZVE0138A 4
MID RIGHT HAND SIDE
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IN-LINE HARNESS CONNECTOR (SPREADER PLATES)
CONNECTOR X22
IN-LINE HARNESS CONNECTOR (SPREADER PLATES)
1 184 (GR) RELAY K-36 ACTIVATION
ZVE0028A 5
ZVE0149A 6
MID LEFT HAND SIDE
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SPREADER PLATE ACTUATOR (M7/R7)
CONNECTOR X56
SPREADER PLATE ACTUATOR (M7/R7)
1 051 (GR) SPREADER PLATES MOTOR CIRCUIT
4 050 (WT) SPREADER PLATES MOTOR CIRCUIT
ZVE0052A 7
ZVE0302A 8
LEFT HAND SIDE REAR
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DRUM VARIATOR SWITCH
CONNECTOR S17
DRUM VARIATOR SWITCH
2A
2B 262 (WT) THRESHING ENGAGED B(+)
3 060 (GR) RELAY K-34 ACTIVATION
4
5A
5B
6
7
8
9
10
ZVE0254A 9
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ZVE0331A 10
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FAN VARIATOR SWITCH
CONNECTOR S18
FAN VARIATOR SWITCH
1 061 (GR) FAN VARIATOR MOTOR CIRCUIT
2A
3 062 (WT) FAN VARIATOR MOTOR CIRCUIT
4 062 (WT) FAN VARIATOR MOTOR CIRCUIT
5A
5B 045 (ZW) GROUND
6 061 (GR) FAN VARIATOR MOTOR CIRCUIT
7
8
9
10
ZVE0255A 11
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ZVE0332A 12
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SPREADER PLATES SWITCH
CONNECTOR S49
SPREADER PLATES SWITCH
1 183 (WT) SPREADER PLATES SWITCH SIGNAL
2A
4
5A
5B
6
7
8
9
10
ZVE0256A 13
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ZVE0336A 14
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A POST MODULE (A25)






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(A.30.A - C.20.F.13)
CS540, CS640, CS520, CS660
INCLINOMETER
CONNECTOR X23
INCLINOMETER (A2)
A 086 (PK) REFERENCE VOLTAGE
B 088 (BL) GROUND
C 032 (GE) INCLINOMETER SIGNAL
ZVE0005A 1
ZVE0143A 2
BELOW FUSE PRINTED CIRCUIT, RIGHT HAND CAB
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CONNECTOR X24
4 092 (GR) SELF-LEVELLING OVERRIDE SWITCH SIGNAL (RH SIDE)
5 093 (GR) SELF-LEVELLING OVERRIDE SWITCH SIGNAL (LH SIDE)
7 -
9 -
11 -
12 -
13 -
14 -
15 -
16 -
17 -
18 -
19 -
ZVE0006A 3
ZVE0117A 4
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SELF-LEVELLING ACTUATOR (M6)
CONNECTOR X157
SELF-LEVELLING ACTUATOR (M6)
1 089 (BL) SELF-LEVELLING ACTUATION
2 090 (WT) SELF-LEVELLING DECREASING ACTUATION
ZVE0092A 5
ZVE0221A 6
BEHIND THE GEARBOX
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SELF-LEVELLING ACTUATOR POTENTIOMETER (R1)
CONNECTOR X158
SELF-LEVELLING ACTUATOR POTENTIOMETER (R1)
3 088 (BL) GROUND
ZVE0093A 7
ZVE0222A 8
BEHIND THE GEAR BOX
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SELF LEVELLING CLEANING SHOE SWITCH
CONNECTOR S25
SELF LEVELLING CLEANING SHOE SWITCH
1
2A
3 084 (WT) SELF LEVELLING CLEANING SHOE SWITCH SIGNAL
4
5A
5B
6
7 045 (ZW) GROUND
8
9
10
ZVE0257A 9
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ZVE0334A 10
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UPPER SIEVES LEVELLING SWITCH
CONNECTOR S26
UPPER SIEVES LEVELLING SWITCH
1 092 (GR) UPPER SIEVES LEVELLING SWITCH SIGNAL
2A
2B 027 (OR) IGNITION (B+)
3 093 (WT) UPPER SIEVES LEVELLING SWITCH SIGNAL
4
5A
5B
6
7
8
9
10
ZVE0314A 11
ZVE0315A 12
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USE PRINTED CIRCUIT

CCM-MODULE (A8)

CCM-MODULE (A8)



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(A.30.A - C.20.F.14)
CS540, CS640, CS520, CS660
CONNECTOR X15
1 -
2 128 (ZW) GROUND (TRAILER)
3 128 (ZW) GROUND
4 128 (ZW) GROUND
5 -
6 128 (ZW) GROUND
7 -
8 128 (ZW) GROUND
ZVE0109A 1
ZVE0132A 2
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MID RIGHT HAND SIDE
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STRAW WALKER PROTECTION SWITCH (S23)
CONNECTOR X31
2 040 (ZW) GROUND
ZVE0033A 3
ZVE0148A 4
MID LEFT HAND SIDE
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CONNECTOR X85
2 040 (ZW) GROUND
ZVE0060A 5
ZVE0370A 6
STRAW HOOD INNER REAR
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BRAKE LINING WEAR DETECTION (S37.1)
CONNECTOR X167
1 192 (GE) BRAKE LINING SWITCH SIGNAL
ZVE0229A 7
ZVE0233A 8
TOP OF GEARBOX
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CONNECTOR X168
ZVE0230A 9
ZVE0294A 10
TOP OF GEARBOX
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CONNECTOR X169
ZVE0231A 11
ZVE0295A 12
TOP OF GEARBOX
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CONNECTOR X170
ZVE0232A 13
ZVE0296A 14
TOP OF GEARBOX
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BRAKE OIL LEVEL SWITCH
CONNECTOR S41
BRAKE OIL LEVEL SWITCH
1 192 (GE) BRAKE OIL LEVEL SWITCH SIGNAL
1 128 (ZW) GROUND
VFIL04CS0124A0A 15
VFIL04CS0143A0A 16
LEFT HAND SIDE, CAB FLOOR
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PARKING BRAKE SWITCH
CONNECTOR S42
PARKING BRAKE SWITCH
1 137 (GE) PARKING BRAKE SWITCH SIGNAL
1 128 (ZW) GROUND
VFIL04CS0139A0A 17
VFIL04CS0143A0B 18
LEFT HAND SIDE, CAB FLOOR
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A POST MODULE (A25)





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(A.30.A - C.20.F.15)
CS540, CS640, CS520, CS660
GROUNDSPEED SENSOR (B7)
CONNECTOR X27
GROUNDSPEED SENSOR (B7)
1 112 (ZW) GROUND
ZVE0030A 1
ZVE0145A 2
TOP OF GEAR BOX
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FANSPEED SENSOR (B8)
CONNECTOR X28
FANSPEED SENSOR (B8)
1 112 (ZW) GROUND
ZVE0031A 3
ZVE0146A 4
MID LEFT HAND SIDE
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DRUMSPEED SENSOR (B9)
CONNECTOR X29
DRUMSPEED SENSOR (B9)
1 112 (ZW) GROUND
ZVE0032A 5
ZVE0147A 6
MID LEFT HAND SIDE
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STRAW CHOPPER SPEED SENSOR (B10)
CONNECTOR X30
STRAW CHOPPER SPEED SENSOR (B10)
1 112 (ZW) GROUND
2 075 (GE) STRAW CHOPPER SPEED SENSOR SIGNAL
ZVE0008A 7
ZVE0303A 8
REAR LEFT HAND SIDE
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ROTARY SEPARATOR SPEED SENSOR (B11)
CONNECTOR X32
ROTARY SEPARATOR SPEED SENSOR (B11)
1 112 (ZW) GROUND
2 080 (GE) ROTARY SEPARATOR SPEED SENSOR SIGNAL
ZVE0034A 9
ZVE0150A 10
MID LEFT HAND SIDE
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RETURNS ELEVATOR SPEED SENSOR (B12)
CONNECTOR X33
RETURNS ELEVATOR SPEED SENSOR (B12)
1 112 (ZW) GROUND
2 123 (GE) RETURNS ELEVATOR SENSOR SIGNAL
ZVE0035A 11
ZVE0151A 12
MID LEFT HAND SIDE
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STRAW WALKER SPEED SENSOR (B13)
CONNECTOR X37
STRAW WALKER SPEED SENSOR (B13)
1 112 (ZW) GROUND
ZVE0039A 13
ZVE0155A 14
MID LEFT HAND SIDE
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RIGHT HAND SIDE STRAW WALKER GRAIN LOSS SENSOR (B19)
CONNECTOR X53
RIGHT HAND SIDE STRAW WALKER GRAIN LOSS SENSOR (B19)
1 177 (BL) GROUND
2 178 (GE) RH SIDE STRAW WALKER GRAIN LOSS SENSOR SIGNAL
ZVE0010A 15
ZVE0173A 16
RIGHT HAND SIDE OF STRAW WALKERS
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LEFT HAND SIDE STRAW WALKER GRAIN LOSS SENSOR (B20)
CONNECTOR X54
LEFT HAND SIDE STRAW WALKER GRAIN LOSS SENSOR (B20)
1 177 (BL) GROUND
2 180 (GE) LH SIDE STRAW WALKER GRAIN LOSS SENSOR SIGNAL
ZVE0050A 17
ZVE0174A 18
RIGHT HAND SIDE OF STRAW WALKERS
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SIEVES GRAIN LOSS SENSOR (B21)
CONNECTOR X55
SIEVES GRAIN LOSS SENSOR (B21)
1 177 (BL) GROUND
2 182 (GE) SIEVES GRAIN LOSS SENSOR SIGNAL
ZVE0051A 19
ZVE0175A 20
RIGHT HAND SIDE OF SIEVES GRAIN LOSS SENSOR
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IN-LINE HARNESS CONNECTOR (LEFT HAND SIDE STRAW WALKER GRAIN LOSS SENSOR)
CONNECTOR X83
ZVE0059A 21
MID LEFT HAND SIDE
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SWATH PLATE POSITION SENSOR (B26)
CONNECTOR X97
SWATH PLATE POSITION SENSOR (B26)
1 112 (ZW) GROUND
ZVE0011A 22
ZVE0301A 23
LEFT HAND SIDE REAR
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IN-LINE HARNESS CONNECTOR (STRAW CHOPPER POSITION SENSOR)
CONNECTOR X98
IN-LINE HARNESS CONNECTOR (STRAW CHOPPER POSITION SENSOR)
1 112 (ZW) STRAW CHOPPER POSITION SENSOR GROUND
3 112 (ZW) SWATH PLATE POSITION SENSOR GROUND
ZVE0012A 24
ZVE0325A 25
MID LEFT HAND SIDE
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REEL SPEED SENSOR (B27)
CONNECTOR X147
REEL SPEED SENSOR (B27)
1 112 (ZW) GROUND
ZVE0281A 26
ZVE0280A 27
LEFT HAND SIDE OF HEADER
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IN-LINE HARNESS CONNECTOR (RIGHT HAND SIDE STRAW WALKER GRAIN LOSS SENSOR)
CONNECTOR X152
IN-LINE HARNESS CONNECTOR (RIGHT HAND SIDE STRAW WALKER GRAIN LOSS SENSOR)
ZVE0015A 28
ZVE0216A 29
MID RIGHT HAND SIDE
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CONNECTOR X153
ZVE0089A 30
ZVE0217A 31
MID RIGHT HAND SIDE
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HEADER CONNECTOR



CCM-MODULE (A8)

CCM-MODULE (A8)


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(A.30.A - C.20.F.16)
CS540, CS640, CS520, CS660
CONNECTOR X7
A -
B -
C 212 (OR) IGNITION B(+)
D -
E -
F 213 (RD) B(+)
G -
H 276 (WT) RELAY K-25 POWER SUPPLY
I 215 (GE) HAZARD AND TRAILER INDICATOR WARNING LIGHT SIGNAL
J -
K 128 (ZW) GROUND
L 214 (PU) INDICATOR LIGHT SIGNAL
M 218 (PU) LH SIDE INDICATOR LIGHTS SIGNAL
N 217 (PU) RH SIDE INDICATOR LIGHTS SIGNAL
O -
P 199 (RD) B(+)
Q -
R 200 (WT) ROAD LIGHTS SWITCH SIGNAL
S 210 (PU) MAIN BEAM SWITCH SIGNAL
T 209 (PU) DIP BEAM SWITCH SIGNAL
ZVE0022A 1
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ZVE0123A 2
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PRINTED CIRCUIT (RIGHT HAND SIDE FRONT LIGHTS)
CONNECTOR X45
1 205 (PU) RH SIDE FRONT PARK LIGHTS SIGNAL
2 205 (PU) RH SIDE FRONT PARK LIGHT SIGNAL
3 217 (PU) RH SIDE FRONT INDICATOR LIGHTS SIGNAL
4 217 (PU) RH SIDE FRONT INDICATOR LIGHT SIGNAL
5 217 (PU) RH SIDE FRONT ADDITIONAL INDICATOR LIGHT SIGNAL
6 -
7 205 (PU) RH SIDE FRONT ADDITIONAL PARK LIGHT SIGNAL
8 -
ZVE0045A 3
ZVE0161A 4
RIGHT HAND SIDE CAB HAND RAIL
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LEFT HAND SIDE FRONT LIGHTS (E5)
CONNECTOR X46
LEFT HAND SIDE FRONT LIGHTS (E5)
A 128 (ZW) GROUND
B 202 (PU) LH SIDE FRONT PARK LIGHT SIGNAL
C 218 (PU) LH SIDE FRONT INDICATOR LIGHT SIGNAL
ZVE0046A 5
ZVE0166A 6
LEFT HAND SIDE, OPERATOR’S PLATFORM
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RIGHT HAND SIDE FRONT LIGHTS (E10)
CONNECTOR X47
RIGHT HAND SIDE FRONT LIGHTS (E10)
A 128 (ZW) GROUND
B 205 (PU) RH SIDE FRONT PARK LIGHT SIGNAL
C 217 (PU RH SIDE FRONT INDICATOR LIGHT SIGNAL
ZVE0047A 7
ZVE0162A 8
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WARNING INDICATOR PRINTED CIRCUIT
CONNECTOR X49
1 -
2 -
3 -
4 215 (GE) HAZARD AND TRAILER INDICATOR WARNING LIGHT
5 218 (PU) LH SIDE INDICATOR WARNING LIGHT
6 217 (PU) RH SIDE INDICATOR WARNING LIGHT
ZVE0049A 9
ZVE0170A 10
STEERING COLUMN
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TRAILER SOCKET
CONNECTOR X57
TRAILER SOCKET
R 217 (PU) RH SIDE REAR INDICATOR SIGNAL
L 218 (PU) LH SIDE REAR INDICATOR SIGNAL
31 128 (ZW) BRAKE LIGHT GROUND
54 194 (PU) BRAKE LIGHT SIGNAL
L 202 (PU) LH SIDE REAR PARK LIGHT SIGNAL
58R 205 (PU) RH SIDE REAR PARK LIGHT SIGNAL
ZVE0177A 11
ZVE0176A 12
ABOVE REAR AXLE
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ROAD LIGHTS, FRONT, LEFT HAND
CONNECTOR X59
ROAD LIGHTS, FRONT, LEFT HAND
1 202 (PU) ROAD LIGHTS SIGNAL
2 128 (ZW) GROUND
VFIL04CS0137A0A 13
VFIL04CS0120A0A 14
LEFT HAND SIDE FRONT, UNDER OPERATORS PLATFORM
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ROAD LIGHTS, FRONT, RIGHT HAND
CONNECTOR X62
ROAD LIGHTS, FRONT, RIGHT HAND
1 205 (PU) ROAD LIGHTS SIGNAL
1 128 (ZW) GROUND
VFIL04CS0130A0A 15
VFIL04CS0121A0A 16
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ADDITIONAL RIGHT HAND REAR PARK LIGHT
CONNECTOR X65
ADDITIONAL RIGHT HAND REAR PARK LIGHT
1 206 (PU) PARK LIGHT SIGNAL
1 128 (ZW) GROUND
VFIL04CS0128A0C 17
VFIL04CS0122A0A 18
RIGHT HAND SIDE REAR OPERATORS PLATFORM
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LEFT HAND SIDE HEADLAMP (E12)
CONNECTOR X66
A 023 (PU) LH SIDE MAIN BEAM SWITCH SIGNAL
B 022 (PU) LH SIDE DIP BEAM SWITCH SIGNAL
C 128 (ZW) GROUND
ZVE0053A 19
ZVE0179A 20
LEFT HAND SIDE FRONT
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RIGHT HAND SIDE HEADLAMP (E13)
CONNECTOR X67
RIGHT HAND SIDE HEADLAMP (E13)
A 023 (PU) RH SIDE MAIN BEAM SWITCH SIGNAL
B 022 (PU) RH SIDE DIP BEAM SWITCH SIGNAL
C 128 (ZW) GROUND
ZVE0054A 21
ZVE0178A 22
RIGHT HAND SIDE FRONT
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CONNECTOR X132
1 402 (GE) GRAIN TANK LEVEL INDICATOR LIGHT SIGNAL
2 401 (WT) REVOLVING FLASHING LIGHT SWITCH SIGNAL
3 401 (WT) REVOLVING FLASHING LIGHT SIGNAL
5 -
7 -
8 -
ZVE0083A 23
ZVE0207A 24
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PRINTED CIRCUIT (BRAKE LIGHTS)
CONNECTOR X137
2 - BRAKE LIGHT SIGNAL (STRAW HOOD) LH SIDE
3 - BRAKE LIGHT SIGNAL (TRAILER)
4 - BRAKE LIGHT SIGNAL (ON ARM) LH SIDE
5 - BRAKE LIGHT SIGNAL (ON ARM) RH SIDE
6 194 (PU) BRAKE LIGHT CIRCUIT
7 194 (PU) BRAKE LIGHT CIRCUIT
8 - BRAKE LIGHT SIGNAL (STRAW HOOD) RH SIDE
ZVE0084A 25
ZVE0134A 26
MID RIGHT HAND SIDE
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PRINTED CIRCUIT (LEFT HAND SIDE FRONT LIGHTS)
CONNECTOR X139
1 202 (PU) LH SIDE FRONT PARK LIGHTS AND GRAIN HEAD ILLUMINATION
SIGNAL
2 202 (PU) LH SIDE FRONT PARK LIGHT SIGNAL
5 218 (PU) LH SIDE FRONT ADDITIONAL INDICATOR LIGHT SIGNAL
6 -
7 202 (PU) LH SIDE FRONT ADDITIONAL PARK LIGHT SIGNAL
8 202 (PU) GRAIN HEAD ILLUMINATION SIGNAL
ZVE0212A 27
ZVE0168A 28
LEFT HAND SIDE, UNDER OPERATOR’S PLATFORM
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LEFT HAND SIDE FRONT ADDITIONAL LIGHTS (E6)
CONNECTOR X140
LEFT HAND SIDE FRONT ADDITIONAL LIGHTS (E6)
A 128 (ZW) GROUND
B 202 (PU) LH SIDE ADDITIONAL PARK LIGHT SIGNAL
C 218 (PU) LH SIDE FRONT INDICATOR LIGHT SIGNAL
ZVE0213A 29
ZVE0167A 30
LEFT HAND SIDE, UNDER OPERATOR’S PLATFORM
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IN-LINE HARNESS CONNECTOR (REAR LIGHTS)
CONNECTOR X143
1 128 (ZW) BRAKE LIGHTS GROUND (STRAW HOOD) RH SIDE
2 - BRAKE LIGHTS SIGNAL (STRAW HOOD) RH SIDE
3 202 (PU) LH SIDE REAR PARK LIGHT (STRAW HOOD) SIGNAL
4 -
5 217 (PU) RH SIDE REAR INDICATOR LIGHT (STRAW HOOD) SIGNAL
6 218 (PU) LH SIDE REAR INDICATOR LIGHT (STRAW HOOD) SIGNAL
7 - BRAKE LIGHT SIGNAL (STRAW HOOD) LH SIDE
8 128 (ZW) BRAKE LIGHT GROUND (STRAW HOOD) LH SIDE
ZVE0210A 32
RIGHT HAND SIDE REAR OF STRAW HOOD
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CONNECTOR X144
1 205 (PU) RH SIDE REAR PARK LIGHTS SIGNAL
2 205 (PU) RH SIDE REAR PARK LIGHT (ON ARM) SIGNAL
3 202 (PU) LH SIDE REAR PARK LIGHTS SIGNAL
4 202 (PU) LH SIDE REAR PARK LIGHT (ON ARM) SIGNAL
5 202 (PU) LH SIDE REAR PARK LIGHT (STRAW HOOD) SIGNAL
6 202 (PU) LH SIDE REAR PARK LIGHT (TRAILER) SIGNAL
7 205 (PU) RH SIDE REAR PARK LIGHT (STRAW HOOD) SIGNAL
8 205 (PU) RH SIDE REAR PARK LIGHT (TRAILER) SIGNAL
ZVE0211A 33
ZVE0135A 34
MID RIGHT HAND SIDE
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RIGHT HAND SIDE FRONT ADDITIONAL LIGHTS (E11)
CONNECTOR X145
A 128 (ZW) GROUND
B 205 (PU) RH SIDE ADDITIONAL PARK LIGHT SIGNAL
C 217 (PU) RH SIDE FRONT INDICATOR LIGHT SIGNAL
ZVE0087A 35
ZVE0163A 36
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ROAD LIGHTS AND INDICATOR SWITCH (S53/S55)
CONNECTOR X148
ROAD LIGHTS AND INDICATOR SWITCH (S53/S55)
1 200 (WT) ROAD LIGHTS SWITCH SIGNAL
5 199 (RD) B(+)
7 210 (PU) MAIN BEAM SWITCH SIGNAL
8 199 (RD) B(+)
9 196 (WT) HORN SWITCH SIGNAL
ZVE0214A 37
ZVE0215A 38
STEERING COLUMN
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BRAKE LIGHT SWITCH (S52)
CONNECTOR S52
BRAKE LIGHT SWITCH
VFIL04CS0128A0B 39
VFIL04CS0135A0A 40
UNDER CAB
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DIRECTION INDICATOR SWITCH (S53)

ROAD LIGHTS AND INDICATOR SWITCH
5 199 (RD) B(+)
8 199 (RD) B(+)
ZVE0214A 41
VFIL04CS0125A0A 42
STEERING COLUMN
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HEADER CONNECTOR






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(A.30.A - C.20.F.17)
CS540, CS640, CS520, CS660
LEFT HAND SIDE RAILING HEADLIGHTS
CONNECTOR X196
LEFT HAND SIDE RAILING HEADLIGHTS
A 614 (PU) FLIP-UP KIT HEAD LIGHTS SIGNAL
B 616 (PU) FLIP-UP KIT DIMMED LIGHTS SIGNAL
C 128 (ZW) GROUND
VFIL04CS0157A0B 1
VFIL04CS0166A0A 2
LEFT HAND SIDE RAILING
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RIGHT HAND SIDE RAILING HEADLIGHTS
CONNECTOR X197
RIGHT HAND SIDE RAILING HEADLIGHTS
A 614 (PU) FLIP-UP KIT HEAD LIGHTS SIGNAL
B 616 (PU) FLIP-UP KIT DIMMED LIGHTS SIGNAL
C 128 (ZW) GROUND
VFIL04CS0157A0A 3
VFIL04CS0167A0A 4
RIGHT HAND SIDE RAILING
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HEADER CONNECTOR

X66 LEFT HAND SIDE HEADLAMP (E12) ELECTRICAL POWER SYSTEM - Component
X67 RIGHT HAND SIDE HEADLAMP (E13) ELECTRICAL POWER SYSTEM - Component
X145 RIGHT HAND SIDE FRONT ADDITIONAL ELECTRICAL POWER SYSTEM - Component
LIGHTS (E11) diagram frame 16 (A.30.A-C.20.F.16)
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(A.30.A - C.20.F.18)
CS540, CS640, CS520, CS660
HAZARD WARNING LIGHTS SWITCH
CONNECTOR S54
HAZARD WARNING LIGHTS SWITCH
1 -
2A 214 (PU) INDICATOR LIGHT SIGNAL
2B -
4 213 (RD) B(+)
5A 218 (PU) LH SIDE INDICATOR LIGHTS SIGNAL
5B 217 (PU) RH SIDE INDICATOR LIGHTS SIGNAL
8 128 (ZW) GROUND
9 -
10 -
VFIL04CS0159A0A 1
VFIL04CS0144A0A 2
STEERING COLUMN
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DIRECTION INDICATOR SWITCH (S55)

ROAD LIGHTS AND INDICATOR SWITCH
5 199 (RD) B(+)
8 199 (RD) B(+)
ZVE0214A 3
VFIL04CS0123A0A 4
STEERING COLUMN
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PRINTED CIRCUIT (REAR DIRECTION INDICATORS)
CONNECTOR X154
PRINTED CIRCUIT (REAR DIRECTION INDICATORS)
1 217 (PU) RH SIDE REAR INDICATOR LIGHTS SIGNAL
2 217 (PU) RH SIDE REAR INDICATOR LIGHT (ON ARM) SIGNAL
3 218 (PU) LH SIDE REAR INDICATOR LIGHTS SIGNAL
4 218 (PU) LH SIDE REAR INDICATOR LIGHT (ON ARM) SIGNAL
5 218 (PU) LH SIDE REAR INDICATOR LIGHT (STRAW HOOD) SIGNAL
6 218 (PU) LH SIDE REAR INDICATOR LIGHT (TRAILER) SIGNAL
7 217 (PU) RH SIDE REAR INDICATOR LIGHT (STRAW HOOD) SIGNAL
8 217 (PU) RH SIDE REAR INDICATOR LIGHT (TRAILER) SIGNAL
ZVE0218A 5
ZVE0136A 6
MID RIGHT HAND SIDE
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X45 PRINTED CIRCUIT (RIGHT HAND SIDE ELECTRICAL POWER SYSTEM - Component
FRONT LIGHTS) diagram frame 16 (A.30.A-C.20.F.16)
X49 WARNING INDICATOR PRINTED CIRCUIT ELECTRICAL POWER SYSTEM - Component

TRAILER SOCKET
X57 TRAILER SOCKET ELECTRICAL POWER SYSTEM - Component

USE PRINTED CIRCUIT
X111 USE PRINTED CIRCUIT ELECTRICAL POWER SYSTEM - Component




X139 PRINTED CIRCUIT (LEFT HAND SIDE FRONT ELECTRICAL POWER SYSTEM - Component
LIGHTS) diagram frame 16 (A.30.A-C.20.F.16)
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X143 IN-LINE HARNESS CONNECTOR (REAR ELECTRICAL POWER SYSTEM - Component

LIGHTS) diagram frame 16 (A.30.A-C.20.F.16)
X145 RIGHT HAND SIDE FRONT ADDITIONAL ELECTRICAL POWER SYSTEM - Component
LIGHTS (E11) diagram frame 16 (A.30.A - C.20.F.16)
ROAD LIGHTS SWITCH (S53)
X148 ROAD LIGHTS SWITCH (S53) ELECTRICAL POWER SYSTEM - Component


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(A.30.A - C.20.F.19)
CS540, CS640, CS520, CS660
GRAIN TANK LEVEL 1 SWITCH (S35)
CONNECTOR X41
ZVE0041A 1
ZVE0157A 2
FRONT OF GRAIN TANK
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CONNECTOR X42
ZVE0042A 3
ZVE0158A 4
FRONT OF GRAIN TANK
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STRAW HOOD REVOLVING FLASHING LIGHT (E2)
CONNECTOR X74
STRAW HOOD REVOLVING FLASHING LIGHT (E2)
2 029 (ZW) GROUND
ZVE0056A 5
ZVE0181A 6
STRAW HOOD
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REVOLVING FLASHING LIGHT (CAB ROOF) (E1)
CONNECTOR X93
REVOLVING FLASHING LIGHT (CAB ROOF) (E1)
2 283 (ZW) GROUND
ZVE0063A 7
ZVE0188A 8
REVOLVING FLASHING LIGHT (CAB ROOF)
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CONNECTOR X135
1 413 (RD) B(+)
VFIL04CS0136A0J 9
VFIL04CS0158A0B 10
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CONNECTOR X136
1 413 (RD) B(+)
VFIL04CS0136A0K 11
VFIL04CS0158A0A 12
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IN-LINE HARNESS CONNECTOR REVOLVING FLASHING LIGHT (STRAW HOOD)
CONNECTOR X178
IN-LINE HARNESS CONNECTOR REVOLVING FLASHING LIGHT (STRAW HOOD)
2 029 (ZW) GROUND
ZVE0098A 13
ZVE0236A 14
MID LEFT HAND SIDE
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CONNECTOR X191
1 413 (RD) B(+)
VFIL04CS0136A0D 15
VFIL04CS0140A0E 16
RIGHT HAND SIDE CAB
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REVOLVING FLASHING LIGHT SWITCH
CONNECTOR S34
REVOLVING FLASHING LIGHT SWITCH
1
2A
3 401 (WT) ON-ROAD SIGNAL
4
5A 402 (GE) RELAY K-23 ACTIVATION
5B 129 (GE) GRAIN TANK LEVEL 1 SIGNAL
6
7 283 (ZW) GROUND
8
9
10
ZVE0249A 17
ZVE0347A 18
CAB ROOF
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A-POST MODULE (A25)
X4 A-POST MODULE (A25) ELECTRICAL POWER SYSTEM - Component





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(A.30.A - C.20.F.20)
CS540, CS640, CS520, CS660
IN-LINE HARNESS CONNECTOR (REAR WORK LIGHT)
CONNECTOR X73
IN-LINE HARNESS CONNECTOR (REAR WORK LIGHT)
1 230 (PU) REAR WORK LIGHT SIGNAL
2 129 (ZW) GROUND
ZVE0055A 1
ZVE0180A 2
MID LEFT HAND SIDE
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IN-LINE HARNESS CONNECTOR (LIGHTS)
CONNECTOR X94
IN-LINE HARNESS CONNECTOR (LIGHTS)
A 224 (PU) RH SIDE OUTER OPERATING LIGHT SIGNAL
B 222 (PU) UNLOADING TUBE OPERATING LIGHT SIGNAL
C 228 (PU) OPERATING LIGHT SIGNAL
D 283 (ZW) LH SIDE INNER OPERATING LIGHT GROUND
E 225 (PU) LH SIDE INNER OPERATING LIGHT SIGNAL
F 407 (PU) CENTRAL OPERATING LIGHT SIGNAL
G 283 (ZW) CENTRAL OPERATING LIGHT GROUND
H 283 (ZW) LH SIDE OUTER OPERATING LIGHT GROUND
J -
K 283 (ZW) RH SIDE OUTER OPERATING LIGHT GROUND
L 283 (ZW) LH SIDE SPOT LIGHT SIGNAL
M 283 (ZW) OPERATING LIGHT GROUND
N 283 (ZW) RH SIDE INNER OPERATING LIGHT GROUND
O 225 (PU) RH SIDE INNER OPERATING LIGHT SIGNAL
P 223 (PU) LH SIDE SPOT LIGHT SIGNAL
Q 283 (ZW) RH SIDE SPOT LIGHT SIGNAL
R 403 (PU) LH SIDE OUTER OPERATING LIGHT SIGNAL
S 404 (PU) RH SIDE SPOT LIGHT SIGNAL
T 283 (ZW) UNLOADING TUBE OPERATING LIGHT GROUND
U -
V -
W -
X -
ZVE0064A 3
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ZVE0323A 4
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CONNECTOR X125
1 223 (PU) RELAY K-15.3 ACTUATION ON FUSE 55
4 283 (ZW) GROUND
5 220 (WT) RELAY K-15.1 ACTIVATION
7 068 (ZW) GROUND
ZVE0077A 5
ZVE0200A 6
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CONNECTOR X126
3 -
6 -
ZVE0078A 7
ZVE0201A 8
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CONNECTOR X129
2 246 (WT) MIRROR SWITCH LEFT/RIGHT SIGNAL
3 024 (WT) RELAY K-30 AND K-31 ACTIVATION
6 054 (WT) GROUND WITH THRESHING SWITCH ENGAGED
7 247 (WT) MIRROR SWITCH UP/DOWN SIGNAL
8 252 (WT) RH MIRROR UP/DOWN SIGNAL
9 251 (WT) RH MIRROR LEFT/RIGHT SIGNAL
ZVE0115A 9
ZVE0204A 10
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CONNECTOR X131
1 -
2 227 (WT) WORK LIGHT SWITCH SIGNAL
3 -
4 -
5 -
6 -
7 -
8 -
9 434 (WT) RELAY K-15.3 ACTIVATION
ZVE0082A 11
ZVE0206A 12
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CONNECTOR X133
1 607 (RD) IGNITION B(+)
VFIL04CS0136A0H 13
VFIL04CS0158A0D 14
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CONNECTOR X134
VFIL04CS0136A0I 15
VFIL04CS0158A0C 16
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RIGHT HAND SIDE REAR OPERATING LIGHT (E28)
CONNECTOR X164
RIGHT HAND SIDE REAR OPERATING LIGHT (E28)
1 230 (PU) RH SIDE REAR OPERATING LIGHT SIGNAL
2 128 (ZW) GROUND
ZVE0094A 17
ZVE0227A 18
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LEFT HAND SIDE REAR OPERATING LIGHT (E29)
CONNECTOR X165
LEFT HAND SIDE REAR OPERATING LIGHT (E29)
1 230 (PU) LH SIDE REAR OPERATING LIGHT SIGNAL
2 128 (ZW) GROUND
ZVE0095A 19
ZVE0228A 20
LEFT HAND SIDE REAR
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LEFT HAND SIDE STUBBLE LIGHT (E25)
CONNECTOR X176
LEFT HAND SIDE STUBBLE LIGHT (E25)
1 228 (PU) LH SIDE STUBBLE LIGHT SIGNAL
2 128 (ZW) GROUND
ZVE0096A 21
ZVE0235A 22
LEFT HAND SIDE FRONT
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RIGHT HAND SIDE STUBBLE LIGHT (E26)
CONNECTOR X177
RIGHT HAND SIDE STUBBLE LIGHT (E26)
1 228 (PU) RH SIDE STUBBLE LIGHT SIGNAL
2 128 (ZW) GROUND
ZVE0097A 23
ZVE0234A 24
RIGHT HAND SIDE FRONT
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CONNECTOR X193
VFIL04CS0136A0F 25
VFIL04CS0140A0G 26
RIGHT HAND CAB
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OPERATING LIGHTS SWITCH (S56)
CONNECTOR S56
OPERATING LIGHTS SWITCH
1
2A 221 (WT) SWITCH POSITION 1 SIGNAL
2B 282 (WT) UNLOADING TUBE PROTECTION SWITCH SIGNAL
3 221 (WT) SWITCH POSITION 2 SIGNAL
4
5A 227 (WT) SWITCH POSITION 1 SIGNAL
6 220 (WT) SWITCH POSITION 2 SIGNAL
7 283 (ZW) GROUND
8
9 227 (WT) OPERATING LIGHTS SWITCH ILLUMINATION
10
ZVE0246A 27
ZVE0343A 28
CAB ROOF
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CAB DOOR SWITCH (S57)
CONNECTOR S57
CAB DOOR SWITCH
1 284 (BL) CAB INTERIOR LIGHT SWITCHED GROUND
VFIL04CS0156A0A 29
VFIL04CS0145A0A 30
CAB DOOR FRAME
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STUBBLE LIGHTS SWITCH (S67)
CONNECTOR S67
STUBBLE LIGHTS SWITCH
1
2A
2B 227 (WT) OPERATING LIGHTS SWITCH SIGNAL
3 280(WT) STUBBLE LIGHTS SWITCH SIGNAL
4
5A
5B
6
7 068(ZW) GROUND
8
9
10
ZVE0248A 31
ZVE0345A 32
CAB ROOF
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SPOT LIGHTS SWITCH (S68)
CONNECTOR S68
SPOT LIGHTS SWITCH
1
2A
2B 227 (WT) OPERATING LIGHTS SWITCH SIGNAL
3 434 (WT) SPOT LIGHTS SWITCH SIGNAL
4
5A
5B
6
7 068 (ZW) GROUND
8
9
10
ZVE0247A 33
ZVE0344A 34
CAB ROOF
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X137 PRINTED CIRCUIT (BRAKE LIGHTS) ELECTRICAL POWER SYSTEM - Component


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(A.30.A - C.20.F.21)
CS540, CS640, CS520, CS660
RADIO (A20)
CONNECTOR X107
RADIO (A20)
1 219 (RD) B(+)
2 234 (BR) LEFT SPEAKER (+)
3 232 (BR) RIGHT SPEAKER (+)
4 233 (BL) LEFT SPEAKER (-)
5 231 (BL) RIGHT SPEAKER (-)
6 004 (BL) GROUND
ZVEO069A 1
ZVE0191A 2
RADIO, RIGHT HAND SIDE CAB
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WINDSCREEN WIPER MOTOR (M8)
CONNECTOR X109
WINDSCREEN WIPER MOTOR (M8)
1 (ZW) GROUND
2 -
3 238 (WT) RELAY K-43 ACTUATION B(+)
4 237 (WT) WINDSCREEN WIPER SWITCH SIGNAL
6 -
ZVE0190A 3
ZVE0189A 4
WINDSCREEN WIPER MOTOR
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CONNECTOR X128
2 -
3 -
4 -
5 -
6 -
9 025 (OR) RELAY K-43 ACTIVATION
ZVE0080A 5
ZVE0203A 6
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WINDSCREEN WIPER SWITCH (S58)
CONNECTOR S58
WINDSCREEN WIPER SWITCH
1
2A
5A
6 025 (OR) RELAY K-43 ACTIVATION
7
8
9
10
ZVE0250A 7
ZVE0341A 8
CAB ROOF
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WINDSCREEN WASHER SWITCH (S59)
CONNECTOR S59
WINDSCREEN WASHER SWITCH
1
2A
3 239 (WT) WINDSCREEN WASHER PUMP SIGNAL
4
5A
5B
6
7
8
9
10
ZVE0251A 9
ZVE0342A 10
CAB ROOF
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(A.30.A - C.20.F.22)
CS540, CS640, CS520, CS660
LEFT HAND SIDE MIRROR (M13)
CONNECTOR X104
LEFT HAND SIDE MIRROR (M13)
1 249 (BR) LH MIRROR LEFT/RIGHT MOTOR SIGNAL
2 249 (GN) LH MIRROR UP/DOWN MOTOR SIGNAL
3 248 (OR) LH MIRROR UP/DOWN MOTOR SIGNAL
4 250 (GE) LH MIRROR LEFT/RIGHT MOTOR SIGNAL
ZVE0066A 1
LEFT HAND SIDE MIRROR
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RIGHT HAND SIDE MIRROR (M12)
CONNECTOR X105
RIGHT HAND SIDE MIRROR (M12)
1 245 (BR) RH MIRROR UP/DOWN MOTOR SIGNAL
2 245 (GN) RH MIRROR LEFT/RIGHT MOTOR SIGNAL
3 252 (OR) RH MIRROR UP/DOWN MOTOR SIGNAL
4 251 (GE) RH MIRROR LEFT/RIGHT MOTOR SIGNAL
ZVE0067A 2
RIGHT HAND SIDE MIRROR
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ADDITIONAL MIRROR (GERMAN) (M11)
CONNECTOR X106
ADDITIONAL MIRROR (GERMAN) (M11)
A 245 (GN) GERMAN MIRROR MOTOR SIGNAL
B 254 (ZW) GERMAN MIRROR UP/DOWN MOTOR SIGNAL
C 251 (WT) GERMAN MIRROR LEFT/RIGHT MOTOR SIGNAL
ZVE0068A 3
ADDITIONAL MIRROR (GERMAN) - RIGHT HAND SIDE
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CONNECTOR X130
6 -
9 251 (WT)
ZVE0081A 4
ZVE0205A 5
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IN-LINE HARNESS CONNECTOR (LEFT HAND SIDE MIRROR)
CONNECTOR X179
IN-LINE HARNESS CONNECTOR (LEFT HAND SIDE MIRROR)
1 248 (BL) LH MIRROR UP/DOWN MOTOR SIGNAL
2 249 (PK) LH MIRROR SIGNAL
3 250 (GE) LH MIRROR LEFT/RIGHT MOTOR SIGNAL
4 -
ZVE0099A 6
ZVE0169A 7
LEFT HAND SIDE,UNDER OPERATOR’S PLATFORM
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IN-LINE HARNESS CONNECTOR (RIGHT HAND SIDE MIRROR)
CONNECTOR X180
IN-LINE HARNESS CONNECTOR (RIGHT HAND SIDE MIRROR)
1 252 (BR) RH MIRROR UP/DOWN MOTOR SIGNAL
2 251 (BL) RH MIRROR LEFT/RIGHT MOTOR SIGNAL
3 245 (GN) RH MIRROR MOTOR SIGNAL
4 251 (WT) GERMAN MIRROR LEFT/RIGHT MOTOR SIGNAL
5 254 (ZW) GERMAN MIRROR UP/DOWN MOTOR SIGNAL
6 -
ZVE0100A 8
ZVE0164A 9
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MIRROR ADJUSTMENT SWITCH (S62)
CONNECTOR S62
MIRROR ADJUSTMENT SWITCH
A 285 (OR) IGNITION B(+)
B 250 (WT) LEFT HAND SIDE MIRROR SIGNAL
C 249 (WT) LEFT HAND SIDE MIRROR SIGNAL
D 248 (WT) LEFT HAND SIDE MIRROR SIGNAL
E 247 (WT) RIGHT HAND SIDE MIRROR SIGNAL
F 245 (WT) RIGHT HAND SIDE MIRROR SIGNAL
G 246 (WT) RIGHT HAND SIDE MIRROR SIGNAL
H 435 (ZW) GROUND
ZVE0243A 10
ZVE0348A 11
CAB ROOF
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ADDITIONAL MIRROR SWITCH (GERMAN) (S63)
CONNECTOR S63
ADDITIONAL MIRROR SWITCH (GERMAN)
1
2A
3 024 (WT) ADDITIONAL MIRROR SWITCH SIGNAL
4
5A
5B
6
7 435 (ZW) GROUND
8
9
10
ZVE0245A 12
ZVE0346A 13
CAB ROOF
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(A.30.A - C.20.F.23)
CS540, CS640, CS520, CS660
BLOWER FAN (A23)
CONNECTOR X81
BLOWER FAN (A23)
1 -
2 441 (GE) CLIMATE CONTROL MODULE SIGNAL
3 283 (ZW) GROUND
4 283 (ZW) GROUND
7 -
9 -
10 -
11 -
13 -
15 -
16 -
ZVE0057A 1
ZVE0322A 2
FRONT OF CAB ROOF
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CLIMATE CONTROL MODULE (A24)
CONNECTOR X82
CLIMATE CONTROL MODULE (A24)
1 -
2 208 (PK) PARK LIGHT SIGNAL
10 298 (GE) A/C PRESSURE SWITCH SIGNAL
11 297 (GE) A/C PRESSURE SENSORS GROUND
12 296 (GE) A/C HIGH PRESSURE SWITCH SIGNAL
13 283 (ZW) CLIMATE CONTROL MODULE GROUND
14 -
15 -
16 -
17 -
18 -
19 -
20 -
21 -
22 -
ZVE0058A 3
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ZVE0324A 4
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AIR CONDITIONING PRESSURE SWITCH (B71/S70)
CONNECTOR X182
AIR CONDITIONING PRESSURE SWITCH (B71/S70)
A 297 (GE) A/C PRESSURE SENSORS GROUND CIRCUIT
B 296 (GE) A/C HIGH PRESSURE SWITCH SIGNAL
C 298 (GE) A/C LOW PRESSURE SWITCH SIGNAL
ZVE0101A 5
ZVE0238A 6
FRONT OF ENGINE
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AIR CONDITIONING COMPRESSOR CLUTCH SOLENOID (Y11)
CONNECTOR X183
AIR CONDITIONING COMPRESSOR CLUTCH SOLENOID (Y11)
A 405 (WT) RELAY K-51 ACTUATION
B 040 (ZW) AIR CONDITIONING COMPRESSOR CLUTCH GROUND
ZVE0102A 7
ZVE0328A 8
FRONT OF ENGINE
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CCM OVERRIDE SWITCH
S80 CCM OVERRIDE SWITCH ELECTRICAL POWER SYSTEM - Component

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(A.30.A - C.20.F.24)
CS540, CS640, CS520, CS660
IN-LINE HARNESS CONNECTOR (POWER REAR AXLE SOLENOID Y22)
CONNECTOR X13
IN-LINE HARNESS CONNECTOR (POWER REAR AXLE SOLENOID Y22)
1 128 (ZW) GROUND
2 508 (WT) POWER REAR AXLE SOLENOID SIGNAL
ZVE0113A 1
LEFT HAND SIDE OF BATTERY CASE
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RIGHT HAND VERTICAL KNIFE RELAY (K71)
CONNECTOR X43
RIGHT HAND VERTICAL KNIFE RELAY (K71)
ZVE0043A 2
ZVE0159A 3
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LEFT HAND VERTICAL KNIFE RELAY (K70)
CONNECTOR X44
LEFT HAND VERTICAL KNIFE RELAY (K70)
ZVE0160A 5
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POWER REAR AXLE SWITCH (S8)
CONNECTOR S8
POWER REAR AXLE SWITCH
1 -
2A -
3 508 (WT) POWER REAR AXLE SWITCH SIGNAL
4 -
5A -
7 045 (ZW) GROUND
8 -
10 -
ZVE0259A 6
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ZVE0338A 7
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VERTICAL KNIVES SWITCH (S69)
CONNECTOR S69
VERTICAL KNIVES SWITCH
1
2A
2B 057 (BL) GROUND (WITH HEADER ENGAGED)
4
5A
5B 057 (BL) GROUND (WITH HEADER ENGAGED)
8
9
10
VFIL04CS0163A0A 8
VFIL04CS0164B0A 9
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CCM OVERRIDE SWITCH
S80 CCM OVERRIDE SWITCH ELECTRICAL POWER SYSTEM - Component

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ELECTRICAL POWER SYSTEM - Electrical standard (A.30.A -

C.20.D.40)
CS540, CS640, CS520, CS660
WIRES
The wiring diagram is drawn following the DIN 40719 standards.
Each page contains a part of the complete wiring diagram, not necessarily a complete group.
Color code
Ten colours of wires are used on the combine, each color having its specific signification.
• Red (rd):+ 12 V without passing the ignition switch
• Black (zw): directly earthed to the frame
• White (wt): connected with the pin of a switch which engages a system that increases something (e.g.
increase of drum rpm)
• Grey (gr): connected with the pin of a switch which disengages a system that decreases something
• Brown (br): signal wire from the rpm monitor to a sensor
• Blue (bl): earth of sensors through the monitor
• Green (gn): wire to non rpm sensors (e.g. engine oil pressure, temperature, etc)
• Orange (or): lighting
• Yellow (ge): lighting
• Purple (pu): to rear direction indicator lights.
• Rose (pk): ref. voltage.

On the upper part of the page, the + 12 V lines are drawn.
The line at the top (first line) always is at + 12 V (when the main battery switch is engaged).
Lines 2 and 3 have + 12 V when relays K6 and K9 are energized. This happens when the ignition switch is engaged.
52865 1
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WIRE IDENTIFICATION
The wiring diagram is marked as follows:
• X16p01: Connector X16, position 01
• 893: Wire number
• 6: Wire section is 6 mm2
• wt: Wire color (white)
• X108p02: Connector X108, position 02
52866 2
This information is printed at regular distances on the wire itself, e.g.
X16/01 < - 893 - > X108/02
Thick drawn lines in the wiring diagrams do not exist as a wire but are lines in the printed circuit.
51844 3
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FUSES
A fuse can protect one or more electrical circuits.
When more circuits are protected, the first time the fuse is mentioned, the drawing is as follows (really connected):
51845 4
The other circuits that are protected by the same fuse are drawn as follows:
(*): The line reference indicates the line on which all connections (lines) with that particular fuse are mentioned.
51846 5
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SYMBOLS
All symbols used in the wiring diagram are drawn according to the DIN 40719 standard and are marked with a
letter and a number.
Each letter represents a group of similar components.
The letters used can be found in following list:
Letter Component Example

A Monitors, prints Radio, CB, displays
B Commutator from non-electrical into Sensor, horn, sender elements of water, air, oil
electrical signals, and vice versa temperature and pressure, buzzer
C Condensers
D Accumulator equipment Accumulators
E Lighting All lamps, except warning lights, dashboard lights
F Safety components All fuses
G Generators Battery, alternator
H Control components All control lamps
K Relays All relays, flasher unit
L Inductive components Coils in relays Motors
M Motors Variator motors, ventilator, actuators
N Amplifier, controller Voltage controller
P Measuring instrument Clock, fuel and water temperature gauge
R Resistances Potentiometer, preheating
S Switch All switches
T Transformer Ignition coils
U Commutator from electrical signals Frequence commutator, converter
into other electrical signals
V Semi-conductors Diodes, transistors, thyristors
W Wiring looms, antennas CB and radio antenna, coax wires
X Connectors All connectors, plugs
Y Mechanical components electrically Hydraulic valve, electromagnetic clutches, electrical
energized valve on injection pump.
Z Electrical filter Suppressor
The letters used can be found in following list:
SYMBOL DESCRIPTION
Electrical motor, actuator
Lamp
Double-acting lamp
Diode
Led (light emitting diode)
Fuse
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SYMBOL DESCRIPTION
Socket (female)
Plug in (male)
Automatic fuse
Buzzer
Inductive sensor
Horn
Ignition switch
Flashing unit
Solenoid for control valves
Battery
Gauge
Electromagnetic clutch
Adjustable resistance
Bipolar switch
Loudspeaker
Alternator
Wiper motor
Electrical starter motor
Normally closed switch, manually controlled
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SYMBOL DESCRIPTION
Normally open switch, mechanical control by pedal
Normally open switch, mechanically controlled
Normally open switch, mechanically controlled
Normally closed switch, mechanically controlled
Normally open switch, controlled by a pressure sender
Normally closed switch, controlled by under-pressure
Normally closed switch, controlled by over-pressure
Normally open switch, controlled by a temperature sender
Normally closed switch, controlled by a level indicator
Normally open switch, controlled by the grain level indicator
Relay
Air conditioning ventilation motor
Mirror motor
The switches are drawn in the position as they are removed from the combine.
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RELAYS
A fuse can protect one or more electrical circuits.
NOTE: Never use relays with a diode parallel with the coil or without a suppressor. Relays with terminal references
1 - 2 - 3 - 4 - 5 (see diagrams) have no suppressor and are soldered to the printed circuit.
The relays can be recognized by the drawing on the relay housing (Figures 6 to 8).
Use relays with drawing as shown in Figure 6.
Do not use relays with drawings as shown in Figures 7 and 8.
52867 6
52868 7
52869 8
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ELECTRICAL POWER SYSTEM - Electrical symbol (A.30.A -

C.20.C.40)
CS540, CS640, CS520, CS660
Ref. Line Group / Series

1a 10 STARTER CIRCUIT
CS540 1260 > 1260
CS640 1260 > 1260
1b 10 STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)
CS540 1320 > 1324
CS640 1320 > 1324
1c 10 STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)
CS540 1364 > 1372
CS640 1364 > 1372
1d 10 STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)
CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....
1e 10 STARTER CIRCUIT (ELECTRICAL HEADER REVERSING)
CS520 1376 > ....
2a 350 PRE HEATING
CS540 1260 > 1260
CS640 1260 > 1260
2b 350 PRE HEATING
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....
3a 520 CAN CONNECTION
CS540 1260 > 1260
CS640 1260 > 1260
3b 520 CAN CONNECTION
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....
4a 690 ENGINE PROTECTION
CS520 1376 > ....
CS540 1260 > ....
CS640 1260 > ....
CS660 1376 > ....
5a 1030 REEL CONTROL + UNLOADING TUBE OPEN/CLOSE
CS540 1260 > 1260
CS640 1260 > 1260
5b 1030 REEL CONTROL + UNLOADING TUBE OPEN/CLOSE
CS540 1320 > 1324
CS640 1320 > 1324
5c 1030 REEL CONTROL + UNLOADING TUBE OPEN/CLOSE
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
6a 1370 HEADER HEIGHT CONTROL
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CS540 1260 > 1260
CS640 1260 > 1260
6b 1370 HEADER HEIGHT CONTROL
CS540 1320 > 1324
CS640 1320 > 1324
6c 1370 HEADER HEIGHT CONTROL
CS540 1364 > 1372
CS640 1364 > 1372
6d 1370 HEADER HEIGHT CONTROL
CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....
7a 1880 AUTOMATIC HEADER HEIGHT CONTROL
CS540 1260 > 1260
CS640 1260 > 1260
7b 1880 AUTOMATIC HEADER HEIGHT CONTROL
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....
8a 2050 THRESHING ENGAGEMENT
CS540 1260 > 1260
CS640 1260 > 1260
8b 2050 THRESHING ENGAGEMENT
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....
9a 2390 HEADER ENGAGEMENT + HYDRAULIC REVERSING SYSTEM
CS540 1260 > 1260
CS640 1260 > 1260
9b 2390 HEADER ENGAGEMENT + HYDRAULIC REVERSING SYSTEM
CS540 1320 > 1372
CS640 1320 > 1372
9c 2390 HEADER ENGAGEMENT + HYDRAULIC REVERSING SYSTEM
CS520 1376 > .... (with lateral flotation)
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....
9d 2390 HEADER ENGAGEMENT + ELECTRICAL REVERSING SYSTEM
CS520 1376 > .... (without lateral flotation)
10a 2720 REEL SPEED CONTROL + REEL SPEED SYNCHRONISATION
CS540 1260 > 1324
CS640 1260 > 1324
10b 2720 REEL SPEED CONTROL + REEL SPEED SYNCHRONISATION
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
11a 2900 UNLOADING TUBE ENGAGEMENT
CS540 1260 > 1260
CS640 1260 > 1260
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11b 2900 UNLOADING TUBE ENGAGEMENT
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....
12a 3060 DRUM VARIATOR, FAN VARIATOR AND SPREADER PLATES
CS540 1260 > 1260
CS640 1260 > 1260
12b 3060 DRUM VARIATOR, FAN VARIATOR AND SPREADER PLATES
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....
13a 3400 SIEVE LEVELLING SYSTEM
CS540 1260 > 1324
CS640 1260 > 1324
13b 3400 SIEVE LEVELLING SYSTEM
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
14a 3920 CONTROL INSTRUMENTS
CS540 1260 > 1260
CS640 1260 > 1260
14b 3920 CONTROL INSTRUMENTS
CS540 1320 > 1324
CS640 1320 > 1324
14c 3920 CONTROL INSTRUMENTS
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
15a 4090 SHAFT SPEED SENSORS + GRAIN LOSS SENSORS
CS540 1260 > 1260
CS640 1260 > 1260
15b 4090 SHAFT SPEED SENSORS + GRAIN LOSS SENSORS
CS540 1320 > 1324
CS640 1320 > 1324
15c 4090 SHAFT SPEED SENSORS + GRAIN LOSS SENSORS
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
16a 4430 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
CS540 1260 > 1260
CS640 1260 > 1260
16b 4430 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
CS540 1320 > 1324
CS640 1320 > 1324
16c 4430 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
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16d 4430 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
CS540 1320 > 1324
CS640 1320 > 1324
16e 4430 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
17a 4940 FLIP-UP KIT
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....
18a 5100 DIRECTION INDICATOR LIGHTS
CS540 1260 > 1260
CS640 1260 > 1260
18b 5100 DIRECTION INDICATOR LIGHTS
CS540 1320 > 1324
CS640 1320 > 1324
18c 5100 DIRECTION INDICATOR LIGHTS
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
19a 5440 REVOLVING FLASHLIGHTS AND GRAIN TANK LEVEL INDICATOR
CS520 1376 > ....
CS540 1260 > ....
CS640 1260 > ....
CS660 1376 > ....
20a 5780 OPERATING LIGHTS
CS540 1260 > 1324
CS640 1260 > 1324
20b 5780 OPERATING LIGHTS
CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....
21a 6460 WINDSCREEN WIPER/WASHER + RADIO
CS540 1260 > ....
CS640 1260 > ....
22a 6800 MIRROR CONTROL
CS520 1376 > ....
CS540 1260 > ....
CS640 1260 > ....
CS660 1376 > ....
23a 7310 AIR CONDITIONING
CS540 1260 > 1260
CS640 1260 > 1260
23b 7310 AIR CONDITIONING
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....
24a 7820 VERTICAL KNIVES
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CS540 1260 > 1260
CS640 1260 > 1260
24b 7820 VERTICAL KNIVES + POWERED REAR AXLE
CS540 1320 > 1372
CS640 1320 > 1372
24c 7820 VERTICAL KNIVES + POWERED REAR AXLE
CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....
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ELECTRICAL POWER SYSTEM - Electrical symbol (A.30.A -

C.20.C.40)
CS540, CS640, CS520, CS660
A. Prints and Monitors
Code Description Line

A1. Printed circuit - header height control 1980
A2. Printed circuit - self levelling cleaning system 3580
A3. Printed circuit - warning lights steering column 4560
A8. CCM - Reverse drive buzzer + polarization protection 1090
A8. CCM - CAN connection 80
A8. CCM - Reel 2730
A8. CCM - Header 2480
A8. CCM - Header + lateral flotation 1570
A8. CCM - Header height control 1930
A8. CCM - Self-levelling cleaning system 3510
A8. CCM - Sensors 4240
A8. CCM - Threshing engagement 2070
A20. Radio 6590
A23. Blower air conditioning 7630
A24. Control panel air conditioning 7440
A24. Module 7440
A25. A-post - Unloading tube open/close 2930
A25. A-post - Alternator 80
A25. A-post - CAN connection 580
A25. A-post - Pneumatic pressure threshing engagement 2320
A25. A-post - Grain tank level indicator + revolving flashlights 5470
A25. A-post - LED controls 3980
A25. A-post - Engine protection 750
A25. A-post - Direction indicator signal 5350
A25. A-post - Spreader plates indicator 3320
A25. Module 7630
A28. Printed circuit - lights print 4550
B.Sensors, limit switches, buzzers, speakers

B1. Reverse drive buzzer 1050
B2. Engine coolant temperature contact 730
B3. Engine oil temperature contact 750
B4. Engine oil pressure contact 790
B5. Engine temperature sensor 4020
B6. Fuel level potentiometer 4040
B7. Ground speed sensor 4260
B8. Fan variator rpm sensor 4240
B9. Drum variator rpm sensor 4220
B10. Straw chopper rpm sensor 4200
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B11. Rotary separator rpm sensor 4320
B12. Returns elevator rpm sensor 4280
B13. Straw walker rpm sensor 4300
B15. Engine air filter restriction contact 3960
B16. Hydrostatic oil pressure contact 710
B17. Hydrostatic oil temperature contact 690
B18. Oil pressure sensor (header lift cylinders) 1560
B19. Straw walker grain loss sensor (RH) 4120
B20. Straw walker grain loss sensor (LH) 4140
B21. Sieves grain loss sensor 4160
B22. Horn 4480
B23. Speaker (LH) 6600
B24. Speaker (RH) 6600
B25. A-post module (buzzer) 750
B26. Swath plate position sensor 4180
B27. Reel speed rpm sensor 4340
B71. High pressure contact - air conditioning 7380
E.Lighting

E1. Revolving flashlight - cab roof 5530
E2. Revolving flashlight - straw hood 5530
E3. Direction indicator, LH on straw hood 5360
E3. Brake light, LH on straw hood 4420
E3. Brake light, LH on straw hood 4470
E3. Parking light, LH on straw hood 4750
E3. Parking light, LH on straw hood 4780
E4. Direction indicator, RH on straw hood 5360
E4. Brake light, RH on straw hood 4480
E4. Parking light, RH on straw hood 4830
E4. Parking light, RH on straw hood 4850
E5. Direction indicator, LH front 5260
E5. Parking light, LH front 4670
E5. Parking light, LH front 4700
E6. Additional direction indicator, LH front 5260
E6. Additional parking light, LH front 4690
E6. Additional parking light, LH front 4720
E7. Grain head illumination, LH 4700
E8. Grain head illumination, RH 4720
E10. Direction indicator, RH front 5260
E10. Parking light, RH front 4800
E10. Parking light, RH front 4820
E11. Additional direction indicator, RH front 5260
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E11. Additional parking light, RH front 4810
E12. Head light, LH 4580
E13. Head light, RH 4610
E19. Unloading tube operating light 6220
E20. Spot light, RH 5960
E21. Spot light, LH 5950
E22. Inner operating light, RH 6110
E23. Inner operating light, LH 6100
E24. Grain tank light 6040
E25. Stubble light, LH 5840
E26. Stubble light, RH 5850
E27. Operating light, RH 5870
E28. Rear operating light, RH 6150
E29. Rear operating light, LH 6160
E30. Cab interior light 6240
E31. Central operating light 6060
E32. Direction indicator, LH on arm 5360
E32. Brake light, LH on arm 4500
E32. Brake light, LH on arm 4510
E32. Parking light, LH on arm 4730
E32. Parking light, LH on arm 4760
E33. Direction indicator, RH on arm 5360
E33. Brake light, RH on arm 4510
E33. Brake light, RH on arm 4520
E33. Parking light, RH on arm 4840
E33. Parking light, RH on arm 4860
E35. Outer operating light, LH 6010
E36. Outer operating light, RH 6020
E37. Additional head light, LH on railing 4970
E38. Additional head light, RH on railing 5000
F.Fuses

F2. 25A - Self-levelling cleaning system 3500
F3. 15A - Hydraulic valves, reverse drive buzzer 1040
F3. 15A - Header height control 1370
F4. 15A - Engine protection 750
F5. 25A - Power after threshing engaged 2130
F6. 15A - Brake lights 4440
F6. 15A - Air conditioning 7330
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F7. 10A - Grain tank level indicator 5450
F7. 10A - Manual adjustment self levelling cleaning system 3440
F7. 10A - 12 V plug - operator’s seat 320
F8. 10A - CCM + A-post module, before contact 630
F9. 15A - Revolving flashlights 5490
F10. 25A - Reel variator 2810
F10. 25A - Drum variator, fan variator 3180
F11. 15A - CCM + A-post module, after contact 520
F12. 15A - Road mode 2210
F13. 40A - Drum variator 120
F13. 40A - Drum variator 3130
F14. 40A - Starter circuit + 12 V plug - cigarette lighter 290
F15. 40A - Main fuse - after contact 5490
F16. 15A - Direction indicator lights 5210
F18. 15A - Hazard warning lights 5220
F19. 25A - Parking lights 4490
F20. 15A - Parking lights, LH 4660
F20. 15A - Parking lights, LH 4690
F21. 15A - Parking lights, RH 4780
F21. 15A - Parking lights, RH 4800
F22. 10A - Additional parking lights 4900
F22. 10A - Additional parking lights 4910
F22. 10A - Air conditioning control panel lighting 7350
F23. 10A - Head lights 4580
F23. 15A - Head lights 4590
F24. 10A - Dimmed lights 4610
F24. 15A - Dimmed lights 4640
F25. 40A - 12 V - Fuse print 5820
F27. 15A - Power, threshing engaged 2260
F28. 10A - On/off self-levelling cleaning system 3480
F29. 15A - Power relays operating lights 6270
F30. 10A - Unloading tube light 6230
F31. 15A - Inner operating lights 6090
F32. 15A - Stubble lights + operating light, RH 5870
F33. 15A - Rear operating lights 6150
F34. 25A - Windscreen wiper/washer 6470
F34. 25A - Mirror control 6860
F35. 30A - Fan 7580
F51. 15A - Central operating light 6050
F52. 10A - Grain tank light 6030
F53. 15A - Outer operating light, RH 6020
F54. 15A - Outer operating light, LH 6010
F55. 15A - Spot light, LH 5940
F56. 15A - Spot light, RH 5960
F57. 25A - Spreader plates actuator 3280
F61. 40A - Vertical knife, RH 7870
F62. 40A - Vertical knife, LH 7930
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G.Generators, batteries

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
H.Control lights (mostly LEDs)

H1. LED - Alternator 80
H2. LED - Straw walker protection 3950
H4. LED - Grain tank level indicator 5460
H5. LED - Unloading tube open/close 2930
H6. LED - Head lights 4550
H9. Direction indicator warning light 5180
H10. Trailer direction indicator warning light 5170
H11. Ladder protection warning light 750
H12. LED - Engine oil pressure 750
H13. LED - Engine oil + coolant temperature 750
H15. LED - Engine air filter restriction contact 3960
H16. LED - Hydrostatic oil pressure + oil temperature 750
H17. LED - Brake oil level + brake linings wear 4010
H18. LED - Parking brake 3980
H19. LED - Red header height control 1890
H20. LED - Green header height control 1880
H21. LED - Green pneumatic pressure 2320
H22. LED - Red pneumatic pressure 2330
H23. LED - Diagnostic 2790
H40. Dashboard lighting 4880
K.Relays

K1. Relay - Starter circuit 180
K2. 12 V after contact relay 1 (Fuse print) 210
K3. Relay - Engine protection 770
K4. Relay - Engine protection reset 800
K5. Relay - Reel down 1200
K6. Relay - Reel up 1230
K7. Relay - Unloading tube open 1260
K8. Relay - Unloading tube close 1290
K9. Relay - Engagement protection 2240
K9. Relay - Engagement protection 2260
K9. Relay - Threshing engagement 2130
K10. Relay - Header engagement 2440
K11. Relay - Reel variator slow 2810
K12. Relay - Reel variator fast 2850
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K13. Relay - Ladder protection 2170
K14. Relay - Unloading tube light 6220
K15. Relay - Grain tank light + outer operating light 6020
K15. Relay - Inner operating lights 6100
K15. Relay - Spot lights 5950
K15. Relay - Central operating light 6060
K16. Relay - Header engagement 2400
K17. Relay - Operator’s seat switch 2430
K18. Relay - Header up 1410
K19. Relay - Header down 1460
K20. Relay - Reversing mechanism 2500
K23. Relay - Revolving flashlights 5600
K24. Relay - Road mode (header height control) 2080
K25. Relay - Flasher unit 5140
K26. Relay - Parking lights 4510
K28. Relay - Stubble lights 5870
K30. Relay - Mirror control 1 7100
K31. Relay - Mirror control 2 7100
K32. Relay - Rear operating lights 6150
K33. Relay - Drum variator 3130
K33. Relay - Drum variator speed down 3130
K34. Relay - Drum variator 3160
K34. Relay - Drum variator speed up 3160
K35. Relay - Pre heating 410
K36. Relay - Spreader plates 3250
K37. Relay - Spreader plates 3280
K38. Relay - Fan 1 7500
K39. Relay - Fan 2 7540
K40. Relay - Fan 7580
K41. Relay - Air pressure threshing mechanism 2360
K42. Relay - Air pressure threshing mechanism 2310
K43. Relay - Windscreen wiper 6480
K45. Relay - Unloading tube protection 2970
K48. Relay - Flip-up dimmed lights 5040
K49. Relay - Flip-up head lights 5040
K51. Relay - Air conditioning compressor 7450
K52. Relay - Polarization protection 1080
K53. Relay - Rotary dust screen brush 2780
K53. Relay - Rotary dust screen brush 2870
K70. Relay - Vertical knife, RH 7850
K71. Relay - Vertical knife, LH 7900
M.Motors
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M1. Motor - Starter 70
M2. Motor - Electrical header reversing switch. 2540
M3. Motor - Drum variator 3200
M4. Motor - Fan variator 3200
M5. Motor - Reel variator 2820
M6. Actuator - Self-levelling cleaning system 3630
M7. Actuator - Spreader plates 3320
M8. Motor - Windscreen wiper 6470
M9. Pump - Windscreen washer 6530
M11. Motor - Additional mirror (Germany) 7050
M12. Motor - Mirror, RH 6990
M13. Motor - Mirror, LH 6920
M14. Actuator - Rotary dust screen brush 2860
M15. Motor - Vertical knife, RH 7850
M16. Motor - Vertical knife, LH 7900
R.Resistances

R1. Self-levelling potentiometer 3630
R2. Header height sensor 2000
R5. Stubble height setting 1920
R5. Engine temperature sensor 4020
R6. Fuel level potentiometer 4040
R6. Ground pressure setting 1910
R7. Spreader plates position sensor 3330
R8. Autofloat position sensor (LH) 1890
R9. Autofloat position sensor (RH) 1900
R11. Cold start heating element 440
S.Switches

S1. Switch - Main battery 20
S2. Switch - Multi-function handle neutral 180
S3. Switch - Keystart 170
S4. Switch - Reel forward 1150
S5. Switch - Reverse drive buzzer 1050
S6. Switch - Reel rearward 1170
S8. Switch - Powered rear axle 7960
S9. Switch - Engine protection reset + kill stop 820
S10. Switch - Ladder safety 2120
S11. Switch - Reel down 1200
S12. Switch - Reel up 1220
S13. Switch - Unloading tube open 1250
S14. Switch - Unloading tube close 1280
S15. Switch - Threshing engagement 2110
S16. Switch - Header engagement 2400
S17. Switch - Drum variator 3150
S18. Switch - Fan variator 3190
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S20. Switch - Reel variator slow 2800
S21. Switch - Reel variator fast 2820
S22. Switch - Straw walker protection 3940
S23. Switch - Straw walker protection 3940
S25. Switch - Self-levelling cleaning shoe 3460
S26. Switch - Manual control self levelling cleaning system 3440
S27. Switch - Lateral flotation left down 1620
S28. Switch - Lateral flotation right down 1630
S29. Switch - Header up slow 1410
S30. Switch - Header down slow 1470
S31. Switch - Safety on the road 2190
S32. Switch - Unloading tube protection 2990
S33. Switch - Unloading tube engagement 2920
S34. Switch - Revolving flashing light 5560
S35. Switch - Grain tank level 1 5470
S36. Switch - Grain tank level 2 5450
S37. Contact - Brake lining warning 1 3980
S41. Switch - Brake oil level 4000
S42. Switch - Parking brake 3980
S47. Switch - Automatic header height control 1490
S48. Switch - Header height modes selector 1940
S49. Switch - Spreader plates 3240
S50. Switch - Header up fast 1430
S51. Switch - Header down fast 1450
S52. Switch - Brake lights 4440
S53. Switch - Road lights and indicator 4500
S54. Switch - Hazard warning lights 5200
S55. Switch - Direction indicator 5210
S56. Switch - Operating lights 6250
S57. Switch - Cab door 6240
S58. Switch - Windscreen wiper 6530
S59. Switch - Windscreen washer 6530
S62. Switch - Mirror adjustment 6880
S63. Switch - Additional mirror (German) 6840
S65. Switch - Reel synchronization 2730
S66. Switch - Cold start pre-heating 400
S67. Switch - Stubble lights 5890
S68. Switch - Spot lights 5970
S69. Switch - Vertical knives 7400
S70. Low pressure contact air conditioning 7900
S71. High pressure contact air conditioning 7380
S72. Switch - Threshing mechanism pressure 2330
S80. Switch - CCM Override (A126) 1440
S81. Switch - Reversing mechanism 2480
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X.Connectors

X2. Connector - In-line harness (main power supply)
X4. Connector - A-post module (A25)
X5. Connector - In-line harness 290
X6. Connector - Brake solenoid (Y1)
X7. Connector - In-line harness (steering column)
X8. Connector - In-line harness
X9. Connector - 12 V
X11. Connector - Reverse drive buzzer (B1)
X12. Connector - In-line harness (Solenoid valves)
X13. Connector - In-line harness (power rear axle solenoid)
X14. Connector - Engine stop solenoid (Y3)
X15. Connector - Printed circuit (rear lights)
X17. Connector - Drum variator motor (M3)
X18. Connector - Fan variator motor (M4)
X19. Connector - Header
X20. Connector - Reel variator motor (M5)
X21. Connector - Reel synchronization solenoid (Y21)
X22. Connector - In-line harness (spreader plates)
X23. Connector - Inclinometer (A2)
X24. Connector - In-line harness (self levelling cleaning system)
X25. Connector - In-line harness (ground)
X27. Connector - Groundspeed sensor (B7)
X28. Connector - Fanspeed sensor (B8)
X29. Connector - Drumspeed sensor (B9)
X30. Connector - Straw chopper speed sensor (B10)
X31. Connector - Straw walker protection switch (S23)
X32. Connector - Rotary separator speed sensor (B11)
X33. Connector - Returns elevator speed sensor (B12)
X34. Connector - Ladder switch (S10)
X35. Connector - Diagnostic plug
X36. Connector - Unloading tube engagement and rear FWD/RWD switches
(S33, S4, S6)
X37. Connector - Straw walker speed sensor (B13)
X39. Connector - Header height sensor (R2)
X41. Connector - Grain tank level 1 switch (S35)
X42. Connector - Grain tank level 2 switch (S36)
X43. Connector - Right hand vertical knife relay (K71)
X44. Connector - Left hand vertical knife relay (K70)
X45. Connector - Printed circuit (right hand side front lights)
X46. Connector - Left hand side front lights (E5)
X47. Connector - Right hand side front lights (E10)
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X49. Connector - Warning indicator printed circuit
X52. Connector - Header height control printed circuit
X53. Connector - Right hand side straw walker grain loss sensor (B19)
X54. Connector - Left hand side straw walker grain loss sensor (B20)
X55. Connector - Sieves grain loss sensor (B21)
X56. Connector - Spreader plate actuator (M7/R7)
X57. Connector - Header trailer (Ground) 4530
X57. Connector - Header trailer (Ground) 4540
X57. Connector - Header trailer 4760
X57. Connector - Header trailer 4790
X57. Connector - Header trailer, direction indicator left-hand 5360
X57. Connector - Header trailer, direction indicator right-hand 5360
X57. Connector - Header trailer, brake lights 4530
X57. Connector - Header trailer, brake lights 4540
X57. Connector - Header trailer, parking light (right hand) 4850
X57. Connector - Header trailer, parking light (right hand) 4870
X59. Connector - Road lights, front, (left hand) 4650
X59. Connector - Road lights, front, (left hand) 4680
X62. Connector - Road lights, front, (right-hand) 4790
X62. Connector - Road lights, front, right-hand 4810
X65. Connector - Rear, right-hand 4890
X65. Connector - Additional right hand rear park light 4880
X66. Connector - Left hand side head lamp (E12)
X67. Connector - Right hand side head lamp (E13)
X73. Connector - In-line harness (rear work light)
X74. Connector - Straw hood revolving flashing light (E2)
X75. Connector - Pre-heating fuel pump
X80. Connector - 12 V Plug 330
X81. Connector - Blower fan (A23)
X82. Connector - Climate control module (A24)
X83. Connector - In-line harness (LH side straw walker grain loss sensor)
X85. Connector - Straw walker protection switch (S22)
X87. Connector - Cigarette lighter 260
X88. Connector - Header pressure sensor (B18)
X89. Connector - Threshing engagement switch (S15)
X90. Connector - Header engagement switch (S16)
X92. Connector - Unloading tube protection switch (S32)
X93. Connector - Revolving flashing light (cab roof) (E1)
X94. Connector - In-line harness (lights)
X97. Connector - Swath plate position sensor (B26)
X98. Connector - In-line harness (straw chopper position sensor)
X102. Connector - Rotary dust screen brush (M14)
X104. Connector - Left-hand side mirror (M13)
X105. Connector - Right-hand side mirror (M12)
X106. Connector - Additional mirror (German) (M11)
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X107. Connector - Radio (A20)
X109. Connector - Windscreen wiper motor (M8)
X111. Connector - Fuse printed circuit
X120. Connector - Fuse printed circuit (to be deleted)
X121. Connector - Fuse printed circuit (right-hand console)
X122. Connector - Fuse printed circuit (right-hand console)
X123. Connector - Multi-function handle (right-hand console)
X125. Connector - Lights printed circuit
X137. Connector - Printed circuit (brake lights)
X138. Connector - In-line harness (rotary dust screen brush)
X139. Connector - Printed circuit (left hand side front lights)
X140. Connector - Left hand side front additional lights (E6)
X141. Connector - CCM Module (A8)
X142. Connector - CCM Module (A8)
X143. Connector - In-line harness (rear lights)
X143. Connector - In-line harness (rear lights)
X145. Connector - Right hand side front additional lights (E11)
X147. Connector - Reel speed sensor (B27)
X148. Connector - Road lights and indicator switch (S53/S55)
X152. Connector - In-line harness connector (RH side straw walker grain loss
sensor)
X153. Connector - In-line harness connector (LH side straw walker grain loss
sensor)
X154. Connector - Printed circuit (rear direction indicators)
X155. Connector - Pneumatic solenoids (Y8/Y9/Y15)
X156. Connector - Threshing mechanism pressure switch (S72)
X157. Connector - Self-levelling actuator (M6)
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X158. Connector - Self-levelling actuator potentiometer (R1)
X159. Connector - In-line harness connector
X164. Connector - Right hand side rear operating light (E28)
X165. Connector - Left hand side rear operating light (E29)
X167. Connector - Brake lining warning switch (S37.1)
X176. Connector - Left hand side stubble light (E25)
X177. Connector - Right hand side stubble light (E26)
X178. Connector - In-line harness - revolving flashing light (straw hood)
X179. Connector - In-line harness left hand side mirror
X180. Connector - In-line harness right hand side mirror
X182. Connector - Air conditioning pressure switch (B71/S70)
X183. Connector - Air conditioning compressor clutch solenoid (Y11)
X196. Connector - Left-hand side railing headlights
X197. Connector - Right-hand side railing headlights
Y.Valves

Y1. Solenoid - Brake 2170
Y3. Solenoid - Engine stop 120
Y4. Solenoid - Reel down 1200
Y5. Solenoid - Reel up 1220
Y6. Solenoid - Unloading tube open 1260
Y7. Solenoid - Unloading tube close 1280
Y10. Solenoid - Reversing mechanism 2520
Y11. Solenoid - Air conditioning compressor clutch 7530
Y12. Solenoid - Reversing mechanism 2540
Y13. Solenoid - Reel forward 1140
Y14. Solenoid - Reel rearward 1170
Y16. Solenoid - Lateral float right down 1660
Y17. Solenoid - Lateral float left down 1680
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Y18. Solenoid - Header up 1520
Y19. Solenoid - Header down 1550
Y20. Solenoid - Compensation valve header height control 1570
Y21. Solenoid - Reel synchronization 2740
Y22. Solenoid - Powered rear axle 7940
Y23. Solenoid - Pre-heating fuel pump 450
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ELECTRICAL POWER SYSTEM - Electrical schematic frame 01

(A.30.A - C.20.E.01)
CS540, CS640, CS520, CS660
1a STARTER CIRCUIT
CS540 1260 > 1260
CS640 1260 > 1260

A25. A-post - alternator 80
F1. 80A - main fuse 110
F13. 40A - drum variator 130
F14. 40A - start module / pre-heating 290
G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
H1. LED - alternator 80
K1. Relay - starter circuit 180
K2. 12 V after contact relay 1 (fuse print) 210
M1. Motor - starter 70
S1. Switch - main battery 20
S2. Switch - multi-function handle neutral 170
S3. Switch - ignition 170
X2. In-line harness connector (main power supply) 160
X4. A-post module (A25) 80
X5. In-line harness connector 10
X9. Connector - 12 V plug starter module 290
X14. Engine stop solenoid (Y3) 110
X25. In-line harness connector (ground) 10
X80. Connector - 12 V plug, operator’s seat 330
X87. Connector - cigarette lighter 260
X112. Fuse printed circuit 330
X142. CCM module (A8) 80
Y3. Solenoid - engine stop 110
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Line: 10 - 340
55_a3cs005 1
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1b STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)

CS540 1320 > 1324
CS640 1320 > 1324

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
Line: 10 - 340
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vfil04cs0043h0a 2
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1c STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)

CS540 1364 > 1372
CS640 1364 > 1372

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
Line: 10 - 340
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vfil04cs0044h0a 3
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1d STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
Line: 10 - 340
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vfil04cs0049h0a 4
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1e STARTER CIRCUIT (ELECTRICAL HEADER REVERSING)

CS520 1376 > ....

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
S3. Switch - Ignition 170
Line: 10 - 340
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vfil04cs0046h0a 5
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(A.30.A - C.20.E.02)
CS540, CS640, CS520, CS660
2a PRE HEATING
CS540 1260 > 1260
CS640 1260 > 1260

K35. Relay - pre-heating 410
S66. Switch - cold start pre-heating 410
X75. Pre-heating fuel pump 450
Y23. Solenoid - pre-heating fuel pump 450
Line: 350 - 510
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vfil04cs0161h0a 1
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2b PRE HEATING
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

K35. Relay - pre-heating 410
S66. Switch - cold start pre-heating 410
X75. Pre-heating fuel pump 450
Y23. Solenoid - pre-heating fuel pump 450
Line: 350 - 510
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vfil04cs0162h0a 2
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(A.30.A - C.20.E.03)
CS540, CS640, CS520, CS660
3a CAN CONNECTION
CS540 1260 > 1260
CS640 1260 > 1260

X35. Diagnostic plug 540
Line: 520 - 680
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06_35_44_03 1
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3b CAN CONNECTION
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

Line: 520 - 680
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vfil04cs0048h0a 2
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(A.30.A - C.20.E.04)
CS540, CS640, CS520, CS660
4a ENGINE PROTECTION
CS520 1376 > ....
CS540 1260 > ....
CS640 1260 > ....
CS660 1376 > ....

A25. A-post - engine protection 750
B2. Engine coolant temperature contact 730
B3. Engine oil temperature contact 750
B4. Engine oil pressure contact 790
B16. Hydrostatic oil pressure contact 710
B17. Hydrostatic oil temperature contact 690
B25. A-post module 750
F4. 15A - engine protection 750
H11. Ladder protection warning light 750
H12. LED - engine oil pressure 750
H13. LED - engine oil + coolant temperature 750
H16. LED - hydrostatic oil pressure + oil temperature 750
K3. Relay - engine protection 770
K4. Relay - engine protection reset 800
S9. Switch - engine protection reset + kill stop 820
Line: 690 - 850
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vfil04cs0007h0a 1
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(A.30.A - C.20.E.05)
CS540, CS640, CS520, CS660
5a REEL CONTROL + UNLOADING TUBE OPEN/CLOSE

CS540 1260 > 1260
CS640 1260 > 1260

A8. CCM - reverse drive buzzer + polarisation protection 1090
F3. 15A - hydraulic valves, reverse drive buzzer 1040
K5. Relay - reel down 1200
K6. Relay - reel up 1230
K7. Relay - unloading tube open 1260
K8. Relay - unloading tube close 1290
K52. Relay - polarisation protection 1080
S4. Switch - reel forward 1150
S5. Switch - reverse drive buzzer 1050
S6. Switch - reel rearward 1170
S11. Switch - reel down 1200
S12. Switch - reel up 1220
S13. Switch - unloading tube open 1250
S14. Switch - unloading tube close 1280
X11. Reverse drive buzzer (B1) 1040
X12. In-line harness connector (solenoid valves) 1150
X16. Printed circuit 1070
X36. Unloading tube engagement and FWD/RWD switches (S4, S6, S33) 1150
X122. Fuse printed circuit (right hand console) 1050
X123. Multifunction handle (right hand console) 1180
Y4. Solenoid - reel down 1200
Y5. Solenoid - reel up 1220
Y6. Solenoid - unloading tube open 1260
Y7. Solenoid - unloading tube close 1280
Y13. Solenoid - reel forward 1140
Y14. Solenoid - reel rearward 1170
Line: 1030 - 1360
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55_a3cs007 1
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5b REEL CONTROL + UNLOADING TUBE OPEN/CLOSE

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1030 - 1360
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vfil04cs0008h0a 2
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5c REEL CONTROL + UNLOADING TUBE OPEN/CLOSE

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 1030 - 1360
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vfil04cs0009h0a 3
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(A.30.A - C.20.E.06)
CS540, CS640, CS520, CS660
6a HEADER HEIGHT CONTROL

CS540 1260 > 1260
CS640 1260 > 1260

A8. CCM - header + lateral flotation 1570
F3. 15A - header height control 1370
K18. Relay - header up 1410
K19. Relay - header down 1460
S27. Switch - lateral flotation left down 1620
S28. Switch - lateral flotation right down 1630
S29. Switch - header up slow 1410
S30. Switch - header down slow 1470
S47. Switch - automatic header height control 1490
S50. Switch - header up fast 1430
S51. Switch - header down fast 1450
S80. Switch - CCM override 1440
X88. Header pressure sensor (B18) 1550
X190. Use printed circuit 1600
Y16. Solenoid - lateral float right down 1660
Y17. Solenoid - lateral float left down 1680
Y18. Solenoid - header up 1520
Y19. Solenoid - header down 1550
Y20. Solenoid - compensation valve header height control 1570
Line: 1370 - 1700
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55_a3cs009 1
12119 1 02/07/2004
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6b HEADER HEIGHT CONTROL

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
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vfil04cs0010h0a 2
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6c HEADER HEIGHT CONTROL

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
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vfil04cs0011h0a 3
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6d HEADER HEIGHT CONTROL

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

X190. Fuse printed Circuit 1600
Line: 1370 - 1700
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vfil04cs0012h0a 4
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(A.30.A - C.20.E.07)
CS540, CS640, CS520, CS660
7a AUTOMATIC HEADER HEIGHT CONTROL

CS540 1260 > 1260
CS640 1260 > 1260

A8. CCM - header height ccntrol 1930
H19. LED - red header height control 1890
H20. LED - green header height control 1880
S48. Selector switch - header height modes 1940
X19. Header 1880
X39. Header height sensor (R2) 1990
X52. Header height control printed circuit 1880
Line: 1880 - 2040
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7b AUTOMATIC HEADER HEIGHT CONTROL

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

A8. CCM - header height control 1930
X19. Header 1880
Line: 1880 - 2040
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vfil04cs0013h0a 2
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(A.30.A - C.20.E.08)
CS540, CS640, CS520, CS660
8a THRESHING ENGAGEMENT
CS540 1260 > 1260
CS640 1260 > 1260

A8. CCM - threshing engagement 2070
A25. A-post - pneumatic pressure threshing engagement 2320
F5. 25A - power after threshing engaged 2130
F12. 15A - road mode 2210
F27. 15A - power, threshing engaged 2260
H21. LED - green pneumatic pressure 2320
H22. LED - red pneumatic pressure 2330
K9. Relay - engagement protection 2240
K9. Relay - threshing engagement 2130
K13. Relay - ladder protection 2170
K24. Relay - road mode 2080
K41. Relay - air pressure threshing mechanism 2360
S10. Switch - ladder safety 2120
S15. Switch - threshing engagement 2110
S31. Switch - safety on the road 2190
S72. Pressure switch - threshing mechanism 2330
X6. Brake solenoid (Y1) 2180
X16. Printed circuit (rear lights) 2100
X34. Ladder switch (S10) 2100
X89. Threshing engagement switch (S15) 2110
X155. Pneumatic solenoids (Y8/Y9/Y15) 2300
X156. Threshing mechanism pressure switch (S72) 2310
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Y1. Solenoid - brake 2180
Y15. Solenoid - threshing mechanism engagement 2300
Line: 2050 - 2380
55_a3cs011 1
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A.30.A / 385
8b THRESHING ENGAGEMENT
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

A8. CCM - threshing engagement 2070
A25. A-post - pneumatic pressure threshing engagement 2320
F5. 25A - power after threshing engaged 2130
F12. 15A - road mode 2210
F27. 15A - power, threshing engaged 2260
H21. LED - green pneumatic pressure 2320
H22. LED - red pneumatic pressure 2330
K9. Relay - threshing engagement 2130
K13. Relay - ladder protection 2170
K24. Relay - road mode 2080
S10. Switch - ladder safety 2120
S15. Switch - threshing engagement 2110
S31. Switch - safety on the road 2190
S72. Pressure switch - threshing mechanism 2330
X6. Brake solenoid (Y1) 2180
X34. Ladder switch (S10) 2100
X89. Threshing engagement switch (S15) 2110
X156. Threshing mechanism pressure switch (S72) 2310
Y1. Solenoid - brake 2180
Y15. Solenoid - threshing mechanism engagement 2300
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A.30.A / 386
Line: 2050 - 2380
vfil04cs0014h0a 2
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A.30.A / 387

(A.30.A - C.20.E.09)
CS540, CS640, CS520, CS660
9a HEADER ENGAGEMENT + HYDRAULIC REVERSING SYSTEM

CS540 1260 > 1260
CS640 1260 > 1260

A8. CCM - header 2480
K10. Relay - header engagement 2440
K16. Relay - reader engagement 2400
K17. Relay - operator’s seat switch 2430
K20. Relay - reversing mechanism 2510
S16. Switch - header engagement 2400
S81. Switch - reversing mechanism 2480
X90. Header engagement switch (S16) 2400
X123. Multi-function handle (right hand console) 2480
Y9. Solenoid - header engagement 2450
Y10. Solenoid - reversing mechanism 2520
Line: 2390 - 2550
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06_61_70_01 1
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9b HEADER ENGAGEMENT + HYDRAULIC REVERSING SYSTEM

CS540 1320 > 1372
CS640 1320 > 1372

K29. Relay - cab electrical header reversing 2500
Line: 2390 - 2550
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vfil04cs0050h0a 2
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9c HEADER ENGAGEMENT + HYDRAULIC REVERSING SYSTEM

CS520 1376 > .... (with lateral flotation)
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

K29. Relay - electrical header reversing (cab) 2490
Line: 2390 - 2550
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vfil04cs0016h0a 3
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9d HEADER ENGAGEMENT + ELECTRICAL REVERSING SYSTEM

CS520 1376 > .... (without lateral flotation)

K27. Relay - electrical header reversing 2490
K29. Relay - electrical header reversing (cab) 2490
M2. Motor - electrical header reversing starter 2540
Line: 2390 - 2550
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A.30.A / 394
vfil04cs0061h0a 4
12119 1 02/07/2004
A.30.A / 395

(A.30.A - C.20.E.10)
CS540, CS640, CS520, CS660
10a REEL SPEED CONTROL + REEL SPEED SYNCHRONISATION

CS540 1260 > 1324
CS640 1260 > 1324

A8. CCM - reel 2730
F10. 25A - reel variator 2810
H23. LED - diagnostic 2800
K11. Relay - reel variator slow 2810
K12. Relay - reel variator fast 2850
K53.1. Relay - rotary dust screen brush 2780
K53. Relay - rotary dust screen brush 2870
M5. Motor - reel variator 2830
M14. Actuator - rotary dust screen brush 2870
S20. Switch - reel variator slow 2800
S21. Switch - reel variator fast 2820
S65. Switch - reel synchronisation 2730
X5. Iin-line harness connector 2720
X19. Header 2820
X20. Reel variator motor (M5) 2820
X21. Reel synchronisation solenoid (Y21) 2740
X102. Rotary dust screen brush (M14) 2860
X138. In-line harness connector (rotary dust screen brush) 2860
Y21. Solenoid - reel synchronisation 2740
Line: 2720 - 2880
12119 1 02/07/2004
A.30.A / 396
vfil04cs0018h0a 1
12119 1 02/07/2004
A.30.A / 397
10b REEL SPEED CONTROL + REEL SPEED SYNCHRONISATION

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

A8. CCM - reel 2730
X19. Header 2820
X123. Malfunction handle (right hand console) 2800
X142. CCM moduel (A8) 2740
Line: 2720 - 2880
12119 1 02/07/2004
A.30.A / 398
vfil04cs0019h0a 2
12119 1 02/07/2004
A.30.A / 399

(A.30.A - C.20.E.11)
CS540, CS640, CS520, CS660
11a UNLOADING TUBE ENGAGEMENT

CS540 1260 > 1260
CS640 1260 > 1260

A25. A-post - unloading tube open/close 2940
H5. LED - unloading tube open/close 2940
K45. Relay - unloading tube protection 2970
S32. Switch - unloading tube protection 2990
S33. Switch - unloading tube engagement 2910
X92. Unloading tube protection switch (S32) 2990
X122. Fuse printed circuit (right-hand console) 2990
X127. Lights printed circuit 2960
Y8. Solenoid - unloading tube engagement 3020
Line: 2900 - 3060
12119 1 02/07/2004
A.30.A / 400
06_61_70_04 1
12119 1 02/07/2004
A.30.A / 401
11b UNLOADING TUBE ENGAGEMENT

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

A25. A-post - unloading tube open/close 2940
H5. LED - unloading tube open/close 2940
S32. Switch - unloading tube protection 2990
S33. Switch - unloading tube engagement 2910
X92. Unloading tube protection switch (S32) 2990
X122. Fuse printed circuit (right-hand console) 2990
Y8. Solenoid - unloading tube engagement 3020
Line: 2900 - 3060
12119 1 02/07/2004
A.30.A / 402
vfil04cs0020h0a 2
12119 1 02/07/2004
A.30.A / 403

(A.30.A - C.20.E.12)
CS540, CS640, CS520, CS660
12a DRUM VARIATOR, FAN VARIATOR AND SPREADER PLATES

CS540 1260 > 1260
CS640 1260 > 1260

A25. A-post - spreader plates indicator 3320
F10. 10A - drum variator, fan variator 3180
F57. 25A - spreader plates actuator 3280
K33. Relay - drum variator 3130
K36. Relay - spreader plates 3250
M3. Motor - drum variator 3200
M4. Motor - fan variator 3200
M7. Actuator - spreader plates 3320
S17. Switch - drum variator 3150
S18. Switch - fan variator 3200
S49. Switch - spreader plates 3240
X17. Drum variator motor (M3) 3190
X18. Fan variator motor (M4) 3190
X22. In-line harness connector (spreader plates) 3220
X56. Spreader plate actuator (M7/R7) 3300
Line: 3060 - 3390
12119 1 02/07/2004
A.30.A / 404
55_a3cs013 1
12119 1 02/07/2004
A.30.A / 405
12b DRUM VARIATOR, FAN VARIATOR AND SPREADER PLATES

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

A25. A-post - spreader plates indicator 3320
F10. 25A - drum variator, fan variator 3180
F57. 25A - spreader plates actuator 3280
M3. Motor - drum variator 3200
M4. Motor - fan variator 3200
M7. Actuator - spreader plates 3320
S17. Switch - drum variator 3150
S18. Switch - fan variator 3200
S49. Switch - spreader plates 3240
X17. Drum variator motor (M3) 3190
X18. Fan variator motor (M4) 3190
X22. In-line harness connector (spreader plates) 3220
X56. Spreader plate actuator (M7/R7) 3300
Line: 3060 - 3390
12119 1 02/07/2004
A.30.A / 406
vfil04cs0021h0a 2
12119 1 02/07/2004
A.30.A / 407

(A.30.A - C.20.E.13)
CS540, CS640, CS520, CS660
13a SIEVE LEVELLING SYSTEM

CS540 1260 > 1324
CS640 1260 > 1324

A8. CCM - self levelling cleaning system 3510
F2. 25A - self levelling cleaning system 3500
F7. 10A - manual adjustment self levelling cleaning system 3440
F28. 10A - on/off self levelling cleaning system 3480
M6. Actuator - self levelling cleaning system 3630
R1. Self levelling potentiometer 3630
S25. Switch - self levelling cleaning system 3460
S26. Switch - manual control self levelling cleaning system 3440
X23. Inclinometer (A2) 3580
X24. In-line harness connector (self levelling cleaning system) 3420
X157. Self-levelling actuator (M6) 3620
X158. Self-levelling actuator potentiometer (R1) 3610
X190. Fuse Printed circuit 3580
Line: 3400 - 3730
12119 1 02/07/2004
A.30.A / 408
vfil04cs0022h0a 1
12119 1 02/07/2004
A.30.A / 409
13b SIEVE LEVELLING SYSTEM

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
12119 1 02/07/2004
A.30.A / 410
vfil04cs0023h0a 2
12119 1 02/07/2004
A.30.A / 411

(A.30.A - C.20.E.14)
CS540, CS640, CS520, CS660
14a CONTROL INSTRUMENTS

CS540 1260 > 1260
CS640 1260 > 1260

H2. LED - straw walker protection 3950
H15. LED - engine air filter restriction contact 3960
H17. LED - brake oil level + brake linings wear 4010
H18. LED - parking brake 3980
S22. Switch - straw walker protection 3940
S37. Contact - brake lining warning 1 3980
S41. Switch - bake oil level 4000
S42. Switch - parking brake 3980
X31. Straw walker protection switch (S23) 3930
X167. Brake lining warning switch (S37.1) 3990
X169 Brake lining warning switch (S37.3) 3990
Line: 3920 - 4080
12119 1 02/07/2004
A.30.A / 412
vfil04cs0069h0a 1
12119 1 02/07/2004
A.30.A / 413
14b CONTROL INSTRUMENTS

CS540 1320 > 1324
CS640 1320 > 1324

S41. Switch - brake oil level 4000
Line: 3920 - 4080
12119 1 02/07/2004
A.30.A / 414
vfil04cs0024h0a 2
12119 1 02/07/2004
A.30.A / 415
14c CONTROL INSTRUMENTS

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

S41. Switch - brake oil level 4000
Line: 3920 - 4080
12119 1 02/07/2004
A.30.A / 416
vfil04cs0025h0a 3
12119 1 02/07/2004
A.30.A / 417

(A.30.A - C.20.E.15)
CS540, CS640, CS520, CS660
15a SHAFT SPEED SENSORS + GRAIN LOSS SENSORS

CS540 1260 > 1260
CS640 1260 > 1260

A8. CCM - sensors 4250
X19. Header 4360
X27. Groundspeed sensor (B7) 4280
X28. Fan speed sensor (B8) 4260
X29. Drum speed sensor (B9) 4240
X30. Straw chopper speed sensor (B10) 4220
X32. Rotary separator speed sensor (B11) 4340
X33. Returns elevator speed sensor (B12) 4300
X37. Straw walker speed sensor (B13) 4320
X53. Right hand side straw walker grain loss sensor (B19) 4120
X54. Left hand side straw walker grain loss sensor (B20) 4140
X55. Sieves grain loss sensor (B21) 4160
X83. In-line harness connector (LH side straw walker grain loss sensor) 4140
X97. Swath plate position sensor (B26) 4200
X98. In-line harness connector (straw chopper position sensor) 4200
X147. Reel speed sensor (B27) 4360
X152. In-line harness connector (RH side straw walker grain loss sensor) 4120
Line: 4090 - 4420
12119 1 02/07/2004
A.30.A / 418
55_a3cs016 1
12119 1 02/07/2004
A.30.A / 419
15b SHAFT SPEED SENSORS + GRAIN LOSS SENSORS

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12119 1 02/07/2004
A.30.A / 420
vfil04cs0026h0a 2
12119 1 02/07/2004
A.30.A / 421
15c SHAFT SPEED SENSORS + GRAIN LOSS SENSORS

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12119 1 02/07/2004
A.30.A / 422
vfil04cs0027h0a 3
12119 1 02/07/2004
A.30.A / 423

(A.30.A - C.20.E.16)
CS540, CS640, CS520, CS660
16a PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN

CS540 1260 > 1260
CS640 1260 > 1260

B22. Horn 4480
E3.1. Brake light, LH on straw hood 4460
E3.2. Parking light, LH on straw hood 4750
E4.1. Brake light, RH on straw hood 4480
E4.2. Parking light, RH on straw hood 4830
E5.2. Parking light, LH front 4670
E6.1. Additional parking light, LH front 4690
E10.2. Parking light, RH front 4800
E32.1. Brake light, LH on arm 4510
E32.2. Parking light, LH on arm 4730
E33.1. Brake light, RH on arm 4520
E33.2. Parking light, RH on arm 4840
F6. 15A - brake lights 4440
F19. 15A - parking lights 4490
F20. 15A - parking lights, LH 4660
F21. 15A - parking lights, RH 4780
F22. 10A - additional parking lights 4900
F23. 10A - head lights 4590
F24. 10A - dimmed headlights 4610
H6. LED - head lights 4550
K26. Relay - parking lights 4510
S52. Switch - brake lights 4440
S53. Road lights and indicator switch 4500
X7. In-line harness connector (steering column) 4450
X19. Header 4700
X45. Printed circuit (right hand side front lights) 4800
X46. Left-hand side front lights (E10) 4670
X47. Right-hand side front lights (E10) 4800
12119 1 02/07/2004
A.30.A / 424

X49. Warning indicator printed circuit 4550
X57. Connector - header trailer (ground) 4540
X57. Connector - header trailer 4760
X57. Connector - header trailer, brake lights 4540
X57. Connector - header trailer, parking lights 4850
X59. Connector - road lights, front, left-hand 4660
X62. Connector - road lights, front, right-hand 4790
X65. Additional right-hand rear park light 4880
X66. Left hand side headlamp (E12) 4580
X67. Right-hand side headlamp (E13) 4600
X137. Printed circuit (brake lights) 4450
X139. Printed circuit (left-hand side front lights) 4670
X140. Left-hand side front additional lights (E6) 4690
X143. In-line harness connector rear lights 4450
X145. Right hand side front additional lights (E11) 4810
X148. Road lights and indicator switch (S53) 4480
Line: 4430 - 4930
12119 1 02/07/2004
A.30.A / 425
55_a3cs018 1
12119 1 02/07/2004
A.30.A / 426
16b PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN

CS540 1320 > 1324
CS640 1320 > 1324

B22. Horn 4480
X19. Header 4700
12119 1 02/07/2004
A.30.A / 427

X139. Printed circuit (left hand side front lights) 4670
Line: 4430 - 4930
12119 1 02/07/2004
A.30.A / 428
vfil04cs0028h0a 2
12119 1 02/07/2004
A.30.A / 429
16c PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

B22. Horn 4480
X19. Header 4700
12119 1 02/07/2004
A.30.A / 430

X66. Left-hand side headlamp (E12) 4590
Line: 4430 - 4930
12119 1 02/07/2004
A.30.A / 431
vfil04cs0029h0a 3
12119 1 02/07/2004
A.30.A / 432
16d PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN

CS540 1320 > 1324
CS640 1320 > 1324

B22. Horn 4480
X19. Header 4700
12119 1 02/07/2004
A.30.A / 433

Line: 4430 - 4930
12119 1 02/07/2004
A.30.A / 434
vfil04cs0030h0a 4
12119 1 02/07/2004
A.30.A / 435
16e PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

B22. Horn 4480
S53. Additional road lights and indicator switch 4500
X19. Header 4700
12119 1 02/07/2004
A.30.A / 436

X66. Left-hand side headlamp (E12) 4590
Line: 4430 - 4930
12119 1 02/07/2004
A.30.A / 437
vfil04cs0031h0a 5
12119 1 02/07/2004
A.30.A / 438

(A.30.A - C.20.E.17)
CS540, CS640, CS520, CS660
17a FLIP-UP KIT

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

E37. Additional head light, LH on railing 4970
E38. Additional head light, RH on railing 5000
K48. Relay - flip-up dimmed lights 5040
K49. Relay - flip-up head lights 5040
X19. Header 5070
X67. Right hand side headlamp (E13) 4950
X196. Left hand side railing headlights 4960
X197. Right hand side railing headlights 4990
Line: 4940 - 5100
12119 1 02/07/2004
A.30.A / 439
vfil04cs0032h0b 1
12119 1 02/07/2004
A.30.A / 440

(A.30.A - C.20.E.18)
CS540, CS640, CS520, CS660
18a DIRECTION INDICATOR LIGHTS

CS540 1260 > 1260
CS640 1260 > 1260

A25. A-post - direction indicator signal 5350
F16. 15A - direction indicator lights 5210
F18. 15A - hazard warning lights 5220
K25. Relay - flasher unit 5140
S54. Switch - hazard warning lights 5200
S55. Switch - direction indicator 5210
X4. A-post module 5340
X46. Left hand side front lights (E5) 5250
X47. Right hand side front lights (E10) 5250
X57. Connector - header trailer, direction indicator left-hand 5360
X57. Connector - header trailer, direction indicator right-hand 5360
X140. Left hand side front additional lights (E6) 5250
X154. Printed circuit (rear direction indicators) 5320
12119 1 02/07/2004
A.30.A / 441
Line: 5100 - 5430
55_a3cs021 1
12119 1 02/07/2004
A.30.A / 442
18b DIRECTION INDICATOR LIGHTS

CS540 1320 > 1324
CS640 1320 > 1324

Line: 5100 - 5430
12119 1 02/07/2004
A.30.A / 443
vfil04cs0033h0a 2
12119 1 02/07/2004
A.30.A / 444
18c DIRECTION INDICATOR LIGHTS

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 5100 - 5430
12119 1 02/07/2004
A.30.A / 445
vfil04cs0034h0a 3
12119 1 02/07/2004
A.30.A / 446

(A.30.A - C.20.E.19)
CS540, CS640, CS520, CS660
19a REVOLVING FLASHLIGHTS AND GRAIN TANK LEVEL INDICATOR

CS520 1376 > ....
CS540 1260 > ....
CS640 1260 > ....
CS660 1376 > ....

A25. A-post - grain tank level indicator + revolving flashlights 5470
E1. Revolving flashlight - cab roof 5530
E2. Revolving flashlight - straw hood 5530
F7. 10A - grain tank level indicator 5450
F9. 15A - revolving flashlights 5490
F15. 40A - main fuse - after contact 5490
H4. LED - grain tank level indicator 5460
K23. Relay - revolving flashlights 5600
S34. Switch - revolving flashlights 5560
S35. Switch - grain tank level 1 5470
S36. Switch - grain tank level 2 5450
X41. Grain tank level 1 switch (S35) 5470
X42. Grain tank level 2 switch (S36) 5450
X74. Straw hood revolving flashing light (E2) 5510
X93. Revolving flashing light (cab roof) (E1) 5530
X178. In-line harness connector revolving flashing light (straw hood) 5510
Line: 5440 - 5600
12119 1 02/07/2004
A.30.A / 447
vfil04cs0035h0a 1
12119 1 02/07/2004
A.30.A / 448

(A.30.A - C.20.E.20)
CS540, CS640, CS520, CS660
20a OPERATING LIGHTS

CS540 1260 > 1324
CS640 1260 > 1324

F25. 40A - 12 V - fuse print 5820
F29. 15A - power relays operating lights 6270
F30. 10A - unloading tube light 6230
F31. 15A - inner operating lights 6090
F32. 15A - stubble lights + operating light, RH 5870
F33. 15A - rear operating lights 6150
F51. 15A - central operating light 6050
F52. 10A - grain tank light 6030
F53. 15A - outer operating light, RH 6020
F54. 15A - outer operating light, LH 6010
F55. 15A - spot light, LH 5940
F56. 15A - spot light, RH 5960
K14. Relay - unloading tube light 6220
K15. Relay - grain tank light + outer operating light 6020
K15. Relay - inner operating lights 6100
K15. Relay - spot lights 5950
K15. Relay - central operating light 6060
K28. Relay - stubble lights 5870
K32. Relay - rear operating lights 6150
S56. Switch - operating lights 6250
S57. Switch - cab door 6240
S67. Switch - stubble lights 5890
S68. Switch - spot lights 5970
12119 1 02/07/2004
A.30.A / 449

X73. In-line harness connector (rear work light) 6160
X94. In-line harness connector (lights) 5870
X120. Fuse printed circuit (to be deleted) 5940
X164. Right hand side rear operating light (E28) 6150
X165. Left hand side rear operating light (E29) 6160
X176. Left hand side stubble light (E25) 5840
X177. Right hand side stubble light (E26) 5850
Line: 5780 - 6280
12119 1 02/07/2004
A.30.A / 450
vfil04cs0036h0a 1
12119 1 02/07/2004
A.30.A / 451
20b OPERATING LIGHTS

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

F25. 40A - 12 V - fuse print 5820
F29. 15A - rower relays operating lights 6270
F30. 10A - unloading tube light 6230
F31. 15A - inner operating lights 6090
F32. 15A - stubble lights + operating light, RH 5870
F33. 15A - rear operating lights 6150
F51. 15A - central operating light 6050
F52. 10A - grain tank light 6030
F53. 15A - outer operating light, RH 6020
F54. 15A - outer operating light, LH 6010
F55. 15A - spot light, LH 5940
F56. 15A - spot light, RH 5960
K14. Relay - unloading tube light 6220
K15. Relay - grain tank light + outer operating light 6020
K15. Relay - inner operating lights 6100
K15. Relay - spot lights 5950
K15. Relay - central operating light 6060
K28. Relay - stubble lights 5870
K32. Relay - rear operating lights 6150
S56. Switch - operating lights 6250
S57. Switch - cab door 6240
S67. Switch - stubble lights 5890
S68. Switch - spot lights 5970
12119 1 02/07/2004
A.30.A / 452

X73. In-line harness connector (rear work light) 6160
X94. In-line harness connector (lights) 5870
X164. Right hand side rear operating light (E28) 6150
X165. Left hand side rear operating light (E29) 6160
X176. Left hand side stubble light (E25) 5840
X177. Right hand side stubble light (E26) 5850
Line: 5780 - 6280
12119 1 02/07/2004
A.30.A / 453
vfil04cs0037h0a 2
12119 1 02/07/2004
A.30.A / 454

(A.30.A - C.20.E.21)
CS540, CS640, CS520, CS660
21a WINDSCREEN WIPER/WASHER + RADIO

CS540 1260 > ....
CS640 1260 > ....

A20. Radio 6590
B23. Speaker (LH) 6600
B24. Speaker (RH) 6600
F34. 25A - windscreen wiper/washer 6470
K43. Relay - windscreen wiper 6480
M8. Motor - windscreen wiper 6470
M9. Pump - windscreen washer 6530
S58. Switch - windscreen wiper 6530
S59. Switch - windscreen washer 6530
X107. Radio (A20) 6590
X109. Windscreen wiper motor (M8) 6490
Line: 6460 - 6620
12119 1 02/07/2004
A.30.A / 455
vfil04cs0038h0a 1
12119 1 02/07/2004
A.30.A / 456

(A.30.A - C.20.E.22)
CS540, CS640, CS520, CS660
22a MIRROR CONTROL

CS520 1376 > ....
CS540 1260 > ....
CS640 1260 > ....
CS660 1376 > ....

F34. 25A - mirror control 6860
K30. Relay - mirror control 1 7100
K31. Relay - mirror control 2 7100
M11. Motor - additional mirror (Germany) 7050
M12. Motor - mirror, RH 6990
M13. Motor - mirror, LH 6920
S62. Switch - mirror displacement 6880
S63. Switch - additional mirror displacement 6840
X104. Left hand side mirror (M13) 6900
X105. Right hand side mirror (M12) 6970
X106. Additional mirror (German) (M11) 7040
X179. In-line harness connector left hand side mirror 6900
X180. In-line harness connector right hand side mirror 6970
Line: 6800 - 7130
12119 1 02/07/2004
A.30.A / 457
vfil04cs0042h0a 1
12119 1 02/07/2004
A.30.A / 458

(A.30.A - C.20.E.23)
CS540, CS640, CS520, CS660
23a AIR CONDITIONING

CS540 1260 > 1260
CS640 1260 > 1260

F6. 15A - air conditioning 7330
F22. 10A - air conditioning control panel lighting 7350
F35. 30A fan 7580
K38. Relay - fan 1 7500
K39. Relay - fan 2 7540
K40. Relay - fan 7580
K51. Relay - air conditioning compressor 7450
X81. Blower fan (A23) 7610
X82. Climate control module (A24) 7330
X182. Air conditioning pressure switch (B71/S70) 7370
X183. Air conditioning compressor clutch solenoid (Y11) 7500
Y11. Air conditioning compressor clutch 7530
Line: 7310 - 7640
12119 1 02/07/2004
A.30.A / 459
55_a3cs003 1
12119 1 02/07/2004
A.30.A / 460
23b AIR CONDITIONING

CS520 1376 > ....
CS540 1320 > ....
CS540 1320 > ....
CS660 1376 > ....

F6. 15A - air conditioning 7330
F22. 10A - air conditioning control panel lighting 7350
F35. 30A fan 7580
K38. Relay - fan 1 7500
K39. Relay - fan 2 7540
K40. Relay - fan 7580
K51. Relay - air conditioning compressor 7450
X81. Blower fan (A23) 7610
X82. Climate control module (A24) 7330
X182. Air conditioning pressure switch (B71/S70) 7370
X183. Air conditioning compressor clutch solenoid (Y11) 7500
Y11. Air conditioning compressor clutch 7530
Line: 7310 - 7640
12119 1 02/07/2004
A.30.A / 461
vfil04cs0039h0a 2
12119 1 02/07/2004
A.30.A / 462

(A.30.A - C.20.E.24)
CS540, CS640, CS520, CS660
24a VERTICAL KNIVES

CS540 1260 > 1260
CS640 1260 > 1260

F61. 40A - vertical knife, RH 7870
F62. 40A - vertical knife, LH 7930
K70. Relay - vertical knife, RH 7850
K71. Relay - vertical knife, LH 7900
M15. Motor - vertical knife, RH 7850
M16. Motor - vertical knife, LH 7900
S8. Switch - powered rear axle 7960
S69. Switch - vertical knives 7900
X13. In-line harness connector (power rear axle solenoid) 7940
X43. Right hand vertical knife relay (K71) 7890
X44. Left hand vertical knife rRelay (K70) 7840
Y22. Solenoid - powered rear axle 7940
Line: 7820 - 7980
12119 1 02/07/2004
A.30.A / 463
VFIL04CS0165H0B 1
12119 1 02/07/2004
A.30.A / 464
24b VERTICAL KNIVES + POWERED REAR AXLE

CS540 1320 > 1372
CS640 1320 > 1372

X43. Right-hand vertical knife relay (K71) 7890
X44. Left-hand vertical knife relay (K70) 7840
Line: 7820 - 7980
12119 1 02/07/2004
A.30.A / 465
VFIL04CS0040H0B 2
12119 1 02/07/2004
A.30.A / 466
24c VERTICAL KNIVES + POWERED REAR AXLE

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

X43. Right-hand vertical knife relay (K71) 7890
X44. Left-hand vertical knife relay (K70) 7840
Line: 7820 - 7980
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VFIL04CS0041H0B 3
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Wiring harness - Overview (A.30.A.88 - C.10.A.10)

CS540, CS640, CS520, CS660
ZVE0350A 1
Lower cab
X159 - In-line Harness connector X163 - In-line Harness connector

X7 - In-line harness connector X36 - Reel switches (S4/S6)
Connectors located in area A
X45 - Printed circuit (R/H side front lights) X145 - R/H side front additional lights (E11)
X47 - Right-hand side front lights (E10) X180 - In-line harness connector (L/H/S mirror)
Connectors located in area B
X66 - Left-hand side head lamp (E12) X176 - Left-hand side stubble light (E25)
X139 - Printed circuit (L/H side front lights) X177 - Right-hand side stubble light (E26)
X140 - L/H side front additional lights (E6) X179 - In-line harness connector (R/H/S mirror)
X46 - Left-hand side front Lights (E5)
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ZVE0349A 2
Main Cab
S42 - Parking brake Switch S57 - Door switch

X81 - Blower fan (A23) X93 - Revolving flashing light (E1)
X141 - CCM Module (A8) X142 - CCM Module (A8)
X162 - In-line harness connector X142 - CCM Module (A8)
X161 - In-line harness connector X160 - In-line harness connector
X109 - Windscreen wiper motor (M8)
X23 - Inclinometer (A2) X114 - Fuse printed circuit

X35 - Diagnostic plug X115 - Fuse printed circuit
X111 - Fuse printed circuit X190 - Fuse printed circuit
X112 - Fuse printed circuit X194 - Fuse printed circuit
X113 - Fuse printed circuit
Connectors located in area B
S3 - Key start switch X9-12 V Connector

S9 - Power rear axle switch X89 - Threshing engagement switch (S15)
S66 - Cold start pre-heating Switch
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Connectors located in area C
S34 - Revolving flash light Switch S63 - Additional mirror Switch (German)
S56 - Operating lights switch S68 - Spot lights switch
S58 - Windscreen wiper Switch X82 - Climate Control Module (A24)
S59 - Windscreen washer Switch X107 - Radio (A20)
S62 - Mirror adjustment Switch
Connectors located in area D
X4 - A-Post module (A25) X129 - Lights printed circuit

X94 - In-line harness connector (lights) X130 - Lights printed circuit
X125 - Lights printed circuit X131 - Lights printed circuit
X126 - Lights printed circuit X132 - Lights printed circuit
X127 - Lights printed circuit X137 - Printed circuit (brake lights)
X128 - Lights printed circuit X138 - In-line harness connector
Connectors located in area E
X2 - In-line harness connector (main power) X26 - In-line harness connector

X24 - In-line harness connector X80-12 V Plug
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ZVE0351A 3
Right-hand side (Self-levelling)
S26 - Manual control self-levelling switch X24 - In-line harness connector (Self-levelling)
X157 - Self-levelling actuator (M6) X158 - Self-levelling actuator pot (R1)
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ZVE0356A 4
Right-hand side (Main frame)
X18 - Fan variator motor (M4) X34 - Ladder switch (S10)

X164 - R/H side rear operating light (E28) X53 - R/H side S/W grain loss sensor (B19)
X55 - L/H side S/W grain loss sensor (B20) X143 - In-line harness connector rear lights
X137 - Printed circuit (brake lights) X152 - In-line harness connector

X144 - Printed circuit (rear lights) X153 - In-line harness connector
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ZVE0355A 5
Left-hand side (Operator’s platform)

X27 - Ground speed sensor (B7) X28 - Fan speed sensor (B8)
X32 - Rotary separator speed sensor (B11) X33 - Returns elevator speed sensor (B12)
X37 - Straw walker speed sensor (B13) X43 - Right-hand vertical knife relay (K71)
X44 - Left-hand vertical knife relay (K70) X88 - Header pressure sensor (B18)
X155 - Pneumatic solenoids (Y8/Y9/Y15) X156 - Threshing mechanism pressure switch (S72)
Y20 - Compensation valve header height control
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ZVE0354A 6
Left-hand side (grain tank)
X39 - Header height sensor (R2) X40 - In-line harness connector

X41 - Grain tank level 1 switch (S35) X42 - Grain tank level 2 switch (S36)
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ZVE0353A 7
Left-hand side (engine compartment)
X17 - Drum variator motor (M3) X25 - In-line harness connector (ground)
X30 - Straw chopper speed sensor (B10) X31 - Straw walker protection switch (S23)
X73 - In-line harness connector (rear work light) X73 - X74 - Revolving flashing light (straw hood) (E2)
In-line harness connector (rear work light)
X97 - Swath plate position sensor (B26) X98 - In-line harness connector
X178 - In-line harness connector
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ZVE0352A 8
Straw hood
S22 - Straw walker protection switch X22 - In-line harness connector

X56 - Spreader plate actuator (M7/R7) X85 - Straw walker protection switch (S22)
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ELECTRICAL POWER SYSTEM - Service instruction (A.30.A -

F.10.A.05)
CS540, CS640, CS520, CS660
Troubleshooting and fault finding of the electrical system should always be carried out in a logical and planned
sequence. Many apparent faults associated with electronic components are often hastily diagnosed and result in the
replacement of expensive components. An extra few minutes confirming the apparent fault will result in a more
positive and cost effective repair.
The monitor is used to indicate, in coded format, any malfunction detected in the electrical and electronic systems.
Two different coded formats are used to indicate concerns; alarms and errors.
An alarm is an indication of some mechanical condition on the vehicle, and alerts the operator to perform necessary
maintenance, or to change operating conditions to correct the alarm condition. Examples of alarms would be to
indicate an engine overheat condition, blocked filters, or improper control operation. Alarms are not used to indicate
faults with electrical circuits.
An error is an indication of a fault with an electrical circuit or component, and alerts the operator that the circuit or
component is no longer functioning. Examples of error messages include open circuits, shorts to ground, or short to
high voltage. These errors are typically the result of wire harness damage, or sensor mis adjustment or failure.
When investigating an electrical concern, the first step is to fully understand the problem. Get a clear description of
the concern from the operator, and if possible, operate the vehicle to confirm the problem.
Diagnostic procedures for each error code are detailed in this manual.
Where the fault finding procedure requires checks for continuity, a visual inspection of the wiring should be made
prior to conducting test to ensure that obvious ‘mechanical’ damage has not occurred to the harness or connectors.
In some cases, use of a multi meter will be necessary to locate the source of the fault. A good quality multi meter,
capable of measuring voltage, current, and resistance of at least 20,000 ohms, is an essential item to perform
fault finding.
IMPORTANT: Use of powered test lights or any 12 volt source to test or activate electrical circuits may result in
internal failure of the computer modules. Never apply a 12 volt source directly to a solenoid or other device
to prevent damage to the combine electrical system.
1. When using a multi meter, it is good practice to
select a high range and work downwards to avoid
damaging the instrument.
IMPORTANT: Care should be used when using the
multimeter. Only use the instrument as instructed to avoid
damage to the internal elements of the microprocessors
on the combine. When checking the continuity of wiring,
sensors or switches, it is necessary to isolate the combine
modules and ensure the key switch is turned off to prevent
possible further damage. The key switch should only be
switched on and the combine modules connected where
specifically instructed in the fault finding procedure.
55_3_55_3_10 1
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2. During fault finding, it will often be necessary to

uncouple connectors for inspection, or to provide
access for testing. When using the combine
on-board diagnostics, uncoupling connectors as
directed in the fault finding procedures will often
be necessary to locate the source of the fault.
Unless specifically noted, connectors should not be
back-probed using test spoons or other tools, to
prevent damage to the connector and wire seals.
CAUTION
Z018 - Never couple or uncouple electrical connectors
while the engine is running, to prevent machine
damage and personal injury due to electrical shock.
WARNING
Z028 - To avoid personal injury, never attempt to
access electrical connectors under the cab while the
engine is running. Accidental contact with the straw
elevator angle sensor or inappropriate access to the
electrical circuits to the modules may cause the straw
elevator to move unexpectedly, resulting in personal
injury or death.
3. If it is found necessary to clean the connectors

a contact spray should be used. DO NOT
USE ANY OTHER METHOD FOR CLEANING
TERMINALS. Do not use a cleaner that contains
Trichloro-ethylene, this solvent will damage the
plastic body of the connector. It is preferable to use
a cleaner with a Freon T.F. base.
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ELECTRICAL POWER SYSTEM - Preliminary test (A.30.A - F.40.A.20)

CS540, CS640, CS520, CS660
NOTE: This section is only intended as a general guide to using a digital multi meter. Always refer to the
manufacturer’s operators manual for correct operation.
1. A multi meter is an electronic measuring device.
The different types of measurement that can be
made depend upon the make and model of the multi
meter. Most types of multi meter have the capacity
to measure:
. Current (A) ac or dc
. Resistance (Ohm)
. Voltage (V) ac or dc
. Continuity (Buzz test)
More expensive multi meters have other functions,
such as the capacity to measure frequency (Hz)
and test diodes.
55_3_55_3_10 1
2. General operation:
Before proceeding with a test, decide on what
is going to be measured (Voltage, Current etc.).
Rotate the dial until the pointer is within the
relevant zone. Within each zone there are different
scales. The scale that is selected will represent
the maximum value that the multi meter will read.
Always select a scale which is greater than the
value that you intend to measure. If you are unsure
of the value to be measured, always select the
highest scale and then reduce the scale once you
have an idea of the measured value.
55_3_55_3_11 2
3. Why are there different scales ?

The closer that the scale is to the measured value,
the more accurate the reading will be e.g. If
measuring the voltage of a battery with the scale set
at 200 V, the display may read 12 V. However, if the
scale was set to 20 V the display may read a more
accurate reading of 12.27 V.
55_3_55_3_12 3
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4. Measuring voltage (Volts):

Set the range dial to either ac or dc volts. Connect
the black test probe to the "COM" terminal and the
red test probe to the "V/ohm" terminal. Place the
test probes across the component to be measured
with the circuit complete (closed). Read off the
display value
55_3_55_3_13 4
5. Measuring current (Amps):

Set the range dial to either ac or dc current. When
measuring current up to 2 amps, connect the red
test probe to the "A" terminal. When measuring
current up to 10 amps, connect the red test probe
to the "10 A" terminal. Always connect the black
test probe to the "COM" terminal. When taking
measurement of current, always break the circuit
and connect the multi meter in series with the circuit.
Read off the display value.
NOTE: For protection, multi meters are usually fused at
10A.
55_3_55_3_14 5
6. Measuring resistance (ohms):

Set the range dial to the desired position. Connect
the red test probe to the "V/ohm" terminal. Connect
the black test probe to the "COM" terminal. If the
resistance being measured is connected in a circuit,
then turn off the power to the circuit. Connect the
test probes to the measuring point and read off the
display value.
55_3_55_3_15 6
7. Continuity (Buzzer) test:

Set the range dial to the "Buzz" position. Connect
the red test probe to the "V/ohms" terminal. Connect
the black test probe to the "COM" terminal. Connect
the test probes to the measuring point. In general, if
the resistance is less than 50 ohms then the buzzer
will sound, indicating continuity.
55_3_55_3_16 7
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8. Buzzers on different multi meters will sound at

different ohmic values, depending on the quality
of the meter. This can often be misleading. For
example, when checking a corroded earth point.
A poor quality multi meter may buzz at 150 ohm,
indicating continuity and no problem. When using a
higher quality multi meter for the same test, it would
not buzz due to the high resistance. When carrying
out such tests, we should always check the value of
resistance as well as listening out for the buzz.
A good connection gives low resistance.
A bad connection gives high resistance.
55_3_55_3_17 8
9. SUMMARY:
Voltage (V):
Connect across the component with the circuit
closed.
Current (A):
Connect in series with the circuit. Circuit closed.
Resistance (Ohm) :
Connect across the component with the circuit open.
Continuity (Buzz):
Connect the meter across the component with the
circuit open. (Always check the value of resistance
as well !!)
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ELECTRICAL POWER SYSTEM - Adjust (A.30.A - F.45.A.01)

CS540, CS640, CS520, CS660
When installing potentio meters, it is important to ensure that they do not bottom out in either direction, to prevent
damage. Most potentio meters have slotted mounting holes to allow some adjustment. Before tightening the
mounting hardware, operate the attaching linkage fully in both directions to confirm proper potentio meter positioning.
The straw elevator angle sensor (1) and optional header stubble height potentio meters (not shown) require further
adjustment to provide proper HHC operation as follows:
IMPORTANT: The total range of the header height sensor (1) should be between 2.5 - 7.5 V.
1. Start the engine and raise the header just enough to
install the header cylinder safety latch.
Stop the engine and turn the ignition key in the
“contact" position.
Press on the “SET" button (1). (fig.2)
55_3_55_3_34 1
2. On the display (6) appears the output voltage of

the header height sensor (1) in mV and should
be between 7 - 7.5 V. If not, adjust the sensor by
loosening the nut (3) (fig.1).
ZDF0434A 2
3. Start the engine and lower the header to the ground.

4. Stop the engine and turn the ignition key in the
“contact" position again.
5. Press on the "SET" button (1). (fig.2)
6. The voltage should be greater than 2.5 V If not,
adjust the sensor until the monitor read out is +/- 3 V.
7. Check now again the value in the upper position
of the header.
8. After adjusting tighten the nut (3) (fig.1).
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Alternator drive system Belt tensioner - Remove (A.30.A.40.49 -

F.10.A.10)
CS540, CS640, CS520, CS660
1. The fan belt (3) should be removed in the following

manner. Attach a 1/2 in. square drive ratchet into
the square hole (5) of the tensioner arm. Rotate
clockwise and remove the fan belt (3) from the pulley
and allow the tensioner to return to its untensioned
position once the belt has been removed.
ZEIL04CS0051A0B 1
2. Remove the tensioner from the pump by loosening

and removing the centre attaching bolt (6).
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Alternator drive system Belt tensioner - Check (A.30.A.40.49 -

F.40.A.11)
CS540, CS640, CS520, CS660
1. Checking of the tensioner assembly operation

should be carried out, with the tensioner assembly
still attached to the front cover. To check the spring
load, place a "break back" torque bar pre-set to,
70-85 Nm (52-63 lb ft) on to the pulley attaching
bolt. Raise the lever up through an arc of 20 °
maximum. If the torque bar does not "break" within
the range a new tensioner assembly is required.
2. Ensure the tensioner pulley (4), rotates freely by
hand. If not replace with new parts.
ZEIL04CS0051A0B 1
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Alternator drive system Belt tensioner - Install (A.30.A.40.49 -

F.10.A.15)
CS540, CS640, CS520, CS660
1. Fit a new pulley to the assembly if required, and

torque the attaching bolt between 46.5 - 60 Nm
(34.5 - 44 lb ft.)
2. To reassemble the arm assembly, position the
tensioner on to the front cover, fit the mounting
bolt (6) through the assembly, and torque the bolt
between 46.5 - 60 Nm (34.5 - 44 lb ft).
ZEIL04CS0051A0B 1
3. Refitment of the fan belt (3) is the reverse of the

removal procedure, but ensure the “Poly-V" belt, is
positioned correctly onto all of the pulleys.
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Alternator drive system Idler pulley - Check (A.30.A.40.57 -

F.40.A.11)
CS540, CS640, CS520, CS660
1. One idler pulley (1) is fitted to the engine. Located

on the right hand side of the engine, near the water
pump.
ZDF0807A 1
2. Check that the idler pulley rotates freely, if tight or

worn, replace with new. Removal and replacement
is by the attaching bolt through the centre of the
idler pulley. Torque the bolt between 46.5 - 60 Nm
(34.5 - 44 lb ft).
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Wiring harness - Replace (A.30.A.88 - F.10.A.30)

CS540, CS640, CS520, CS660
If a wire within the harness is found to be beyond repair or is open circuit, a jumper wire may be installed as a
temporary repair until such time when a new harness assembly can be installed. Use the following procedure to
install an additional wire:
1. Locate the faulty wire using the procedures

described in the fault code charts.
Disconnect the affected connectors.
If fitted carefully roll back the seal between the
connector and harness outer covering.
Remove the pins from the connector blocks of the
affected wire using the appropriate removal tool
found in the harness repair kit.
NOTE: Use the instructions supplied with the kit to ensure
correct pin removal.
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2. From the harness repair kit select the correct

pin for the connectors. Obtain locally the correct
cross-sectional size wire and measure out the
length required by following the harness routing.
Join the new wire to the new pins as described in
the harness repair kit and install one of the pins into
its connector.
If possible attempt to run the new wire within
the existing harness outer covering, if this is not
possible run the wire along the harness, securing
regularly with suitable ties. With the wire correctly
routed instal the second terminal into its connector
block. Replace the connector seal if removed.
To ensure that the repair has been effective check
for continuity of the new wire using a suitable
multi-meter.
NOTE: This is a temporary repair only. Ensure the
damaged cable is replaced as soon as possible to prevent
ingress of water or chemicals.
55_3_55_3_09 2
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Wiring harness - Repair (A.30.A.88 - F.75.C.32)

CS540, CS640, CS520, CS660
The following method to repair wiring is a temporary expedient only. Wiring should be replaced as soon as possible.
Do not attempt to repair the wire on any system sensors as these are sealed and should only be replaced with a
new component.
NOTE: When conducting a cable repair it is important that only RESIN CORED SOLDER is used. Use of other
types of solder may result in further cable damage.
1. Locate damaged portion of cable then cut away
outer protective cover on both sides of the damaged
area.
55_3_55_3_04 1
2. Peel back the cable from both ends of the damaged

area and carefully cut away the inner cable cover at
the damaged area and strip about 13 mm (1/2 in)
of insulation from the wires. Do not cut away any
wire strands.
Using a suitable solvent, clean about 50 mm (2 in)
from each cover end. Clean the grey cable cover
and the individual leads.
Twist two bare leads together for each damaged
lead, being careful to match wire colours, then
solder the leads using resin cored solder. Tape each
repaired lead with vinyl insulation tape.
55_3_55_3_05 2
3. Wind a layer of vinyl insulation tape up to the grey

cable cover at each end of the repair section. Make
a paper trough, then apply silicon rubber compound
(non hardening sealant) over the repaired section
up to the cover ends. Sufficient sealant must be
used to fill the ends of the cut away area.
55_3_55_3_06 3
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4. Allow the compound to cure then cover the area

with insulating tape taking the tape well over each
end of the repair. An overlap of at least 50 mm (2
in) of tape at each end is necessary.
Check to ensure the repair is satisfactory and
secure the repaired cable so that repeat damage
is avoided.
NOTE: This is a temporary repair only. Ensure the
damaged cable is replaced as soon as possible to prevent
ingress of water or chemicals.
55_3_55_3_07 4
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ELECTRICAL POWER SYSTEM - Problem solving (A.30.A -

G.40.A.30)
CS540, CS640, CS520, CS660
OPERATION
Four electrical tests will be required to properly troubleshoot electrical concerns on the combine. Each test is
described in detail. Ensure that all steps are reviewed and followed when testing.
1. Continuity test, short to ground
2. Voltage measurement, short to 12 volts
3. Resistance test for components
4. Continuity test, open circuits
TROUBLESHOOTING
1. ELECTRICAL TEST PROCEDURE 1: CONTINUITY TEST - SHORT TO GROUND CONDITIONS FOR

PERFORMING TESTS:
1. Power OFF, key switch OFF, (sometimes battery
disconnected or fuse pulled out if specified in
procedure).
2. Connectors at each end or ends of circuit
disconnected to prevent false readings.
3. Set meter to measure resistance or ohms, and
measure circuit resistance. Use black lead to make
contact with a plated metal part on the chassis such
as a jump start post if fitted. Make sure the surface of
the part is not corroded. Use the red meter lead to
touch the connector pins, one pin at a time, and avoid
contact with the case of metal connectors.
4. Determine if measured resistance falls within
guidelines specified in the procedure. 3 - 4 ohms
indicates a direct short to chassis ground and must
be located and repaired. Higher resistances usually
indicate circuit paths through modules, and that an
additional connector needs to be disconnected to
perform the test. More than 100K ohms indicates that
the circuit is free of shorts to ground.
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2. ELECTRICAL TEST PROCEDURE 2: VOLTAGE MEASUREMENT OR SHORT TO POSITIVE SUPPLY

VOLTS CONDITIONS FOR PERFORMING SHORT TO POSITIVE SUPPLY TESTS:
1. Key switch ON (sometimes OFF, if specified in
procedure).
2. Connectors at sensor, switch or potentiometer
end disconnected. All other connectors must be
reconnected to perform test.
3. Set meter to measure DC VOLTS, and measure
circuit voltage as illustrated. Use the red meter lead to
touch the connector pins, one pin at a time, and avoid
contact with the case of metal connectors. Use the
black lead to make contact with a plated metal part on
the chassis such as a jump start post if fitted. Make
sure the surface of the part is not corroded.
4. Determine if measured voltage falls within
guidelines specified in the procedure.
ZDF0225A 2
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3. ELECTRICAL TEST PROCEDURE 3: RESISTANCE TEST FOR ELECTRICAL PARTS CONDITIONS

FOR PERFORMING RESISTANCE TEST
1. Disconnect combine part by unplugging electrical
connectors to expose the part assembly connector
for testing.
2. Set electrical meter to measure resistance
or Ohms and insert test probes into connector
terminals specified in procedure. When checking
potentiometers, measure from wiper terminal to
each of the other terminals while TURNING THE
POT SHAFT. This will ensure no open spots escape
detection. When checking rocker or rotary switches,
actuate the switch while measuring for opens and
shorts.
3. Compare measured values to values specified in
the fault code procedures. Allow plus or minus 5
percent of range tolerance for all measurements.
ZDF0224A 3
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4. ELECTRICAL TEST PROCEDURE 4: CONTINUITY TEST - CHECK FOR OPEN CIRCUITS CONDITIONS
FOR PERFORMING CONTINUITY TESTS:
1. Key switch OFF (sometimes disconnect battery or
pull fuses).
2. Connectors at both ends of the circuit disconnected.
All other connectors must be reconnected to perform
test.
3. Set meter to measure resistance or ohms, and
measure circuit resistance as illustrated. Use the
red meter lead to touch the connector pins, one pin
at a time, and avoid contact with the case of metal
connectors. Use the black lead to make contact
with the connector pin at the other end of the circuit.
Avoid contact with other pins in the connector and the
connector case, if it is metal.
4. Determine if measured resistance falls within
guidelines specified in the procedure. If the resistance
is no more than 3 - 4 ohms, the circuit is continuous.
More resistance usually indicates dirty or corroded
terminals in connectors, and 100K ohms indicates an
open circuit.
55_3_55_3_21 4
IMPORTANT: Ensure that all steps are reviewed and followed when testing.
ELECTRICAL POWER SYSTEM - Testing (A.30.A - G.40.A.20)

CS540, CS640, CS520, CS660
NOTE: The batteries must be fully charged and all connections clean and tight. Use a multi-meter for these tests.
CAUTION
Z011 - DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.
WARNING
Z008 - Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock
position. This will eliminate accidental movement of the machine or start-up of power driven equipment.
N° Test Point Expected Result Other Result (Possible Cause)

1 Check for 12 volts at after contact 12 volts Blown fuse #1.
relay terminal 30. If good reading, continue with next Open circuit in fuse printed circuit.
step. Open circuit between fuse printed
circuit and fuse #1, circuit 005 (RD).
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2 Turn the key start "ON". 12 volts Open circuit in fuse printed circuit.
Check for 12 volts at after contact If good reading, continue with next Open circuit between fuse printed
relay terminal 85. step. circuit and key start switch, circuit
031 (RD).
12 volts not available from key start
switch, pin (1), refer to key start
switch test : Start control - Testing
(B.80.A.90 - G.40.A.20) and Start
control Start switch - Testing
(B.80.A.90.82 - G.40.A.20)
3 Turn the key start "OFF". Less than 1 ohm resistance. Open circuit in fuse printed circuit.
Check for ground at after contact If good reading, continue with next Open circuit between fuse printed
relay terminal 86. step. circuit and ground, circuit 069 (ZW).
4 Swap the suspect after contact 12 volts Open circuit in fuse printed circuit.
relay with another known good after If good reading, install a new after
contact relay (1, 2 or 3). contact relay.
Check power to the after contact
relay fuses.
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ELECTRICAL POWER SYSTEM - Problem solving (A.30.A -

G.40.A.30)
CS540, CS640, CS520, CS660
OPERATION
Power distribution consists of the following:

Unswitched battery power is available at all times. The battery positive terminal is connected to the unswitched
power circuit from which all unswitched power circuits are energized. Power is available to all of the following fuses
1, 8, 13, 14, 18, 19, 25, 26, 57, 61 and 62 regardless of the ignition switch position.
Switched battery power is supplied to the system when the ignition system is ON. This switching is controlled by
after contact relay 2, after contact relay 2.1 and after contact relay 2.2.
When the ignition is switched ON, the after contact relays are energized, supplying battery power to fuses 2, 3, 4, 5,
6, 7, 9, 11, 12, 15, 16, and 34.
TROUBLESHOOTING
Before troubleshooting the power distribution system make sure that the following operating conditions are met:
A. The batteries are fully charged and all connections are clean and tight.
B. The transmission is in neutral or park.
C. Check all connectors for full installation, loose, corroded or pushed out terminals.
D. Determine if the power source being investigated is switched or unswitched.
E. If the power source problem is a switched power source, the relay controlling the circuit needs to be
determined and tested.
CAUTION
CAUTION

No power at one fuse. Power supply to fuse Go to fuse/circuit chart to determine power
supply circuit.
No power at switched After contact relay 1 A - After contact relay test. ELECTRICAL
fuses 3, 4, 6, 12, 16. POWER SYSTEM - Testing (A.30.A -
G.40.A.20)
fuses 2, 5, 7. POWER SYSTEM - Testing (A.30.A -
G.40.A.20)
fuses 9, 11, 15, 34. POWER SYSTEM - Testing (A.30.A -
G.40.A.20)
Alternator - Testing (A.30.A.82 - G.40.A.20)

CS540, CS640, CS520, CS660
NOTE: The batteries must be fully charged and all connections clean and tight. Use a multi meter for these tests.
For battery testing and service, see the battery section in the service manual.
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CAUTION
WARNING

1 Place transmission in PARK. 12.8-14.5 volts. High resistance between Battery
Start engine and set at 1200 rpm. If good reading, charging system is and B+ terminal at Alternator,
Measure voltage at battery. operating properly. circuits 001 (RD) and 006 (RD).
Go to next test point.
2 Place negative lead of the Less than 0.4 volts. High resistance between Battery
multimeter to Battery positive If good reading, circuit is okay. and starter terminal 30, circuit 001
terminal and positive lead to starter Continue with next step. (RD).
B+ terminal. Repair/replace wiring as required.
Read voltage.
3 Place positive lead of the multi Less than 0.4 volts. High resistance between starter
meter to B+ terminal of Alternator If good reading, continue with next terminal 30 and B+ terminal at
and negative lead to starter B+ step. Alternator, circuit 006 (RD).
terminal. Repair/replace wiring as required.
Read voltage.
4 Check for 12 volts at the B+ Voltage varies between 12.8 - 14.5 Alternator.
terminal of the Alternator, while volts in response to load applied. Go to next test point.
turning various load on and off If good reading, charging system is
(lights, heater fans etc.) operating properly.
5 Turn the key start “OFF". Less than 1 ohm. High resistance on circuit 007 (ZW)
Measure resistance between If good reading, repair or replace from Alternator to engine ground.
Alternator housing and engine Alternator. Clean surfaces at Alternator and
ground. engine block.
Ensure that all mountings are clean
and tight.
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Alternator - Problem solving (A.30.A.82 - G.40.A.30)

CS540, CS640, CS520, CS660
OPERATION
The alternator (B+) connector is connected to the battery via terminal "B+" on the starter motor and is grounded to
the engine.
The alternator is self exciting and does not require an excitation circuit. Charging system output is controlled by an
integral voltage regulator/brush assembly. The regulator is set to 14.2 volt regulation. The alternator is temperature
compensated so that output will drop as the alternator warms up.
For vehicles equipped with a 7.5 L engine with mechanical governor, the alternator provides engine RPM information
to the CCM through circuit 159 (GE).
Refer to : ELECTRICAL POWER SYSTEM - Electrical schematic frame 01 (A.30.A - C.20.E.01)
TROUBLESHOOTING
Before troubleshooting the starting system make sure that the following operating conditions are met:
C. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals.
CAUTION
CAUTION

Alternator - Low charge
(A.30.A.82 - G.10.G.50)
Alternator - Over charge
(A.30.A.82 - G.10.G.51)
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Battery - Bad voltage (A.30.A.83 - G.30.B.31)

CS540, CS640, CS520, CS660
E640 - OPERATING BATTERY VOLTAGE IS LESS THAN 10 VOLTS OR GREATER THAN 16.8 VOLTS
NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal
operation.
Cause:
Possible failure modes:
1. External power supply connected

2. Faulty main battery switch
3. Faulty battery positive cable
4. Faulty battery negative cable
5. Faulty connector
6. Faulty charging system
Solution:
1. Check the battery connections, main battery switch connections, main battery negative cable ground and
positive connections.
A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is
tight. Repair or replace as required.
B. If the connectors are okay, continue to step 2.

2. Check that the battery power supply has not been connected to an external power supply.
A. If an external power supply is connected, disconnect and test the system for normal operation.
B. If an external power supply is not connected, continue to step 3.

3. Check the main battery switch.
A. Disconnect the connectors from the main battery switch. Turn the main battery switch to the closed
position. Measure the resistance between pin 1 and pin 2, component side. If the resistance is greater
than 5 ohms, remove and replace the main battery switch.
B. If the main battery switch is okay, continue to step 4.

4. Check the battery positive cable for a high resistance.
A. Reconnect the main battery switch connectors. Measure the voltage between the battery positive
terminal, circuit (001) (RD) and the starter motor terminal 30, circuit (001) (RD). If the voltage indicated is
greater than 0.5 volts, remove and replace the battery positive cable.
B. If the voltage is less than 0.5 volts, continue to step 5.

5. Check the battery negative cable for a high resistance.
A. Measure the voltage between the battery negative terminal and ground. If the voltage indicated is
greater than 0.5 volts, remove and replace the battery negative cable.
B. If the voltage is less than 0.5 volts, continue to charging system circuit troubleshooting in chapter 5 of
the electrical system section.
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(A.30.A - C.20.E.01)
1a STARTER CIRCUIT
CS540 1260 > 1260
CS640 1260 > 1260

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
Line: 10 - 340
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55_a3cs005 1
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1b STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)

CS540 1320 > 1324
CS640 1320 > 1324

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
Line: 10 - 340
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vfil04cs0043h0a 2
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1c STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)

CS540 1364 > 1372
CS640 1364 > 1372

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
Line: 10 - 340
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vfil04cs0044h0a 3
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1d STARTER CIRCUIT (HYDRAULIC HEADER REVERSING)

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
Line: 10 - 340
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vfil04cs0049h0a 4
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1e STARTER CIRCUIT (ELECTRICAL HEADER REVERSING)

CS520 1376 > ....

G1. Battery 1 20
G2. Battery 2 40
G3. Alternator 70
S3. Switch - Ignition 170
Line: 10 - 340
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vfil04cs0046h0a 5
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(A.30.A - C.20.E.03)
3a CAN CONNECTION
CS540 1260 > 1260
CS640 1260 > 1260

Line: 520 - 680
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06_35_44_03 1
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3b CAN CONNECTION
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

Line: 520 - 680
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vfil04cs0048h0a 2
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(A.30.A - C.20.E.05)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1030 - 1360
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A.30.A / 515
55_a3cs007 1
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CS540 1320 > 1324
CS640 1320 > 1324

Line: 1030 - 1360
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vfil04cs0008h0a 2
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CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 1030 - 1360
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vfil04cs0009h0a 3
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(A.30.A - C.20.E.13)
CS540 1260 > 1324
CS640 1260 > 1324

Line: 3400 - 3730
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A.30.A / 521
vfil04cs0022h0a 1
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CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
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vfil04cs0023h0a 2
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Battery - Bad voltage (A.30.A.83 - G.30.B.31)

CS540, CS640, CS520, CS660
E641 - KEY VOLTAGE (VOLTAGE AFTER CONTACT) IS LESS THAN 10 VOLTS OR GREATER THAN 16.8
VOLTS
operation.
Cause:
1. External power supply connected

2. Faulty main battery switch
3. Faulty battery positive cable
4. Faulty battery negative cable
5. Faulty connector
6. Faulty harness
7. Faulty fuse printed circuit
8. Faulty central controller module (CCM)
Solution:
1. Check the battery connections, main battery switch connections, main battery negative cable ground and
positive connections, CCM connectors X141 and X142, fuse printed circuit connectors X111 and X112.

2. Check that the battery power supply has not been connected to an external power supply.
A. If an external power supply is connected, disconnect and test the system for normal operation.
B. If an external power supply is not connected, continue to step 3.

3. Check the battery voltage.
A. Measure the battery voltage between the starter motor terminal 30 and ground, if the voltage indicated is
less than 10 volts, continue to step 4.
B. If the battery voltage is greater than 16.8 volts continue to step 9.

4. Check the main battery switch.
A. Disconnect the connectors from the main battery switch. Turn the main battery switch to the closed
position. Measure the resistance between pin 1 and pin 2, component side. If the resistance is greater
than 5 ohms, remove and replace the main battery switch.
B. If the main battery switch is okay, continue to step 5.

5. Check the battery positive cable for a high resistance.
A. Reconnect the main battery switch connectors. Measure the voltage between the battery positive
terminal, circuit (001) (RD) and the starter motor terminal 30 circuit (001) (RD). If the voltage indicated is
greater than 0.5 volts, remove and replace the battery positive cable.

6. Check the battery negative cable for a high resistance.
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A. Measure the voltage between the battery negative terminal and ground. If the voltage indicated is
greater than 0.5 volts, remove and replace the battery negative cable.

7. Check for an open circuit.
A. Check between connector:

X141 pin 2, circuit (110) (OR) and X141 pin 32, circuit (110) (OR)
If an open circuit is indicated, repair or replace the harness as required.
B. If an open circuit is not indicated, continue to step 8.

8. Check the fuse printed circuit for an open circuit.
A. Remove the after contact relays K2.1, K2.2 and K2.3. Check between the fuse printed circuit connector:
X111 pin 2, circuit (110) (OR) and K2.3 terminal 87
If an open circuit is indicated, remove and replace the fuse printed circuit.
B. If an open circuit is not indicated, download the correct level of software. If the fault re-occurs, remove
and replace the CCM.
9. Check if the batteries and the battery connections have been installed correctly.
A. If the batteries and the battery connections are not okay, reconnect or reposition the batteries correctly.
B. If the batteries and the connections are okay, download the correct level of software. If the fault
re-occurs, remove and replace the CCM.

(A.30.A - C.20.E.03)
3a CAN CONNECTION
CS540 1260 > 1260
CS640 1260 > 1260

Line: 520 - 680
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06_35_44_03 1
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3b CAN CONNECTION
CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

Line: 520 - 680
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vfil04cs0048h0a 2
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Index
Alternator - Problem solving (A.30.A.82 - G.40.A.30) 499

CS540, CS640, CS520, CS660
Alternator - Testing (A.30.A.82 - G.40.A.20) 497
CS540, CS640, CS520, CS660
Alternator drive system Belt tensioner - Check (A.30.A.40.49 - F.40.A.11) 485
CS540, CS640, CS520, CS660
Alternator drive system Belt tensioner - Install (A.30.A.40.49 - F.10.A.15) 486
CS540, CS640, CS520, CS660
Alternator drive system Belt tensioner - Remove (A.30.A.40.49 - F.10.A.10) 484
CS540, CS640, CS520, CS660
Alternator drive system Idler pulley - Check (A.30.A.40.57 - F.40.A.11) 487
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Adjust (A.30.A - F.45.A.01) 483
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
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A.30.A / 530
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Component identification (A.30.A - C.40.C.20) 26
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Component localisation (A.30.A - C.40.B.20) 16
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
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A.30.A / 531
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Electrical standard (A.30.A - C.20.D.40) 321
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - General specification (A.30.A - D.40.A.10) 7
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Preliminary test (A.30.A - F.40.A.20) 480
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Service instruction (A.30.A - F.10.A.05) 478
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40) 6
CS540, CS640, CS520, CS660
ELECTRICAL POWER SYSTEM - Testing (A.30.A - G.40.A.20) 495
CS540, CS640, CS520, CS660
Wiring harness - Overview (A.30.A.88 - C.10.A.10) 469
CS540, CS640, CS520, CS660
Wiring harness - Repair (A.30.A.88 - F.75.C.32) 490
CS540, CS640, CS520, CS660
Wiring harness - Replace (A.30.A.88 - F.10.A.30) 488
CS540, CS640, CS520, CS660
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LIGHTING SYSTEM - 40.A
CS540
CS640
CS520
CS660
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A.40.A / 1
Contents
DIAGNOSTIC
LIGHTING SYSTEM - Testing (A.40.A - G.40.A.20) 4

CS540, CS640, CS520, CS660
LIGHTING SYSTEM - Problem solving (A.40.A - G.40.A.30) 5
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Head light
Head light Wiring harness - Testing (A.40.A.11.88 - G.40.A.20) 10
CS540, CS640, CS520, CS660
Head light - Testing (A.40.A.11 - G.40.A.20) 10
CS540, CS640, CS520, CS660
Turn/hazard light
Turn/hazard light Turn switch - Testing (A.40.A.13.83 - G.40.A.20) 11
CS540, CS640, CS520, CS660
Turn/hazard light Hazard switch - Testing (A.40.A.13.90 - G.40.A.20) 12
CS540, CS640, CS520, CS660
Turn/hazard light - Testing (A.40.A.13 - G.40.A.20) 12
CS540, CS640, CS520, CS660
Brake light
Brake light - Testing (A.40.A.14 - G.40.A.20) 13
CS540, CS640, CS520, CS660
Beacon
Beacon Fuse - Testing (A.40.A.15.80 - G.40.A.20) 14
CS540, CS640, CS520, CS660
Beacon Switch - Testing (A.40.A.15.83 - G.40.A.20) 15
CS540, CS640, CS520, CS660
Beacon Wiring harness - Testing (A.40.A.15.88 - G.40.A.20) 15
CS540, CS640, CS520, CS660
Beacon - Testing (A.40.A.15 - G.40.A.20) 16
CS540, CS640, CS520, CS660
Front work light

Front work light - Testing (A.40.A.16 - G.40.A.20) 16
CS540, CS640, CS520, CS660
Rear work light

Rear work light - Testing (A.40.A.17 - G.40.A.20) 17
CS540, CS640, CS520, CS660
Work light
Work light - Testing (A.40.A.30 - G.40.A.20) 18
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
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A.40.A / 2
Center work light
Center work light - Testing (A.40.A.31 - G.40.A.20) 20
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Inner work light

Inner work light - Testing (A.40.A.32 - G.40.A.20) 21
CS540, CS640, CS520, CS660
Middle work light

Middle work light - Testing (A.40.A.33 - G.40.A.20) 21
CS540, CS640, CS520, CS660
Outer work light

Outer work light - Testing (A.40.A.34 - G.40.A.20) 22
CS540, CS640, CS520, CS660
Unloading tube light

Unloading tube light - Testing (A.40.A.35 - G.40.A.20) 23
CS540, CS640, CS520, CS660
Electrical light
Electrical light - Testing (A.40.A.85 - G.40.A.20) 24
CS540, CS640, CS520, CS660
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DISTRIBUTION SYSTEMS - LIGHTING SYSTEM
LIGHTING SYSTEM - Testing (A.40.A - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect light and indicator 12 volts. Blown Fuse #19.
control switch connector X148. If good reading, go to test point 3. Open circuit in Fuse Printed Circuit.
Check for 12 volts at connector Open circuit between fuse printed
X148 (pin 5), circuit 199 (RD). circuit connector X114 (pin 15) and
light and indicator control switch
connector X148 (pin 5), circuit 199
(RD).
2 Measure resistance between Less than 1 ohm. Open circuit between fuse printed
connector X148 (pin 5) and fuse If good reading, install a new Fuse circuit connector X114 (pin 15) and
printed circuit connector X114 (pin Printed Circuit. light and indicator control switch
15), circuit 199 (RD). connector X148 (pin 5), circuit 199
(RD).
3 Install a fused jumper wire between Main headlights operate. Light and Indicator Control Switch.
connector X148 (pin 5) and (pin 7). Headlight circuit(s) are okay.
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LIGHTING SYSTEM - Problem solving (A.40.A - G.40.A.30)

CS540, CS640, CS520, CS660
OPERATION
Exterior lighting consists of the following:

LH and RH headlights
LH and RH stubble lights (if equipped)
LH and RH direction indicators
LH and RH front park lights (if equipped)
LH and RH rear road lights
Cab front center work light
LH and RH cab inner work lights
LH and RH cab mid work lights
LH and RH cab outer headlights
LH and RH side lights
LH and RH rear work lights (if equipped)
Front flashing beacon
Rear flashing beacon (if equipped)
Licence plate light
Unload tube light
Grain tank light
The various lamps are controlled by switches and operated via relays as follows:
Road light switch is powered directly from battery.
Road light switch includes off, low beam, high beam positions, left/right turn positions and horn switch.
Work light switch includes work light switch itself and inner work switch. Inner work switch is powered through LH
center work lights relay when work light switch is closed.
TROUBLESHOOTING
Before troubleshooting the exterior lighting system make sure that the following operating conditions are met:
D. Fuses # 6, 7, 29, 30, 31, 32, 33, 34, 35, 49, 50, 51, 52, 53, 54, 55 and 56 are intact and have power.
E. If one of the work light circuits is not working, try swapping a relay from a working system for a quick and easy
relay check. Otherwise, follow the circuit diagnostic tests to determine the fault.
F. If a bulb is not working, substitute with a known good bulb to verify circuit operation.
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A.40.A / 5
CAUTION
CAUTION

Both head lamps Fuse #19 A - Light and indicator control switch power
inoperative (dipped beam Fuse printed circuit supply test LIGHTING SYSTEM - Testing
and main beam) Circuit(s) (A.40.A - G.40.A.20)
Light and indicator control switch If test A is okay, install a new light and
indicator control switch.
Dipped beams inoperative Fuse #23 B - Dipped beam circuit test Head light -
(both sides) Fuse printed circuit Testing (A.40.A.11 - G.40.A.20)
Circuit(s)
Light and indicator control switch
Main beams inoperative Fuse #24 C - Main beam circuit test Head light
(both sides) Fuse printed circuit Wiring harness - Testing (A.40.A.11.88 -
Circuit(s) G.40.A.20)
Light and indicator control switch
All operating and work Fuse #15, #29 D - Work light switch power supply
lights are inoperative Cab roof printed circuit test Work light - Testing (A.40.A.30 -
Work light switch If test D is okay, install a new work light
switch.
Stubble work lights Stubble work lights relay Swop the relay with a known good relay.
inoperative
Fuse #32 J - Stubble work lights circuit test Front
Cab roof printed circuit work light - Testing (A.40.A.16 -
Stubble light switch
Center work light Center work light relay Swop the relay with a known good relay.
inoperative
Fuse #51 F - Center work light circuit test Center
Inner work lights Inner work light relay Swop the relay with a known good relay.
inoperative
Fuse #31 G - Inner work lights circuit Inner work
Cab roof printed circuit light - Testing (A.40.A.32 - G.40.A.20)
Circuit(s)
Middle work lights Middle work light relay Swop the relay with a known good relay.
inoperative
Fuse #55, #56 H - Middle work lights circuit test Middle
Outer work lights Outer work light / grain tank light relay Swop the relay with a known good relay.
and grain tank light
inoperative
Fuse #52, #53, #54 I - Outer work lights / grain tank light circuit
Cab roof printed circuit test Outer work light - Testing (A.40.A.34
Circuit(s) - G.40.A.20)
Rear work lights Rear Work Lights Relay Swop the relay with a known good relay.
inoperative (Threshing
operation okay)
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Fuse #33 J - Rear Work Lights Circuit Test Rear
Cab Roof Printed Circuit work light - Testing (A.40.A.17 -
Brake lights inoperative Brake light switch If test K is okay, install a new brake light
switch
All direction indicator Light and indicator control switch L - Direction indicator circuit test
lights are inoperative Circuit(s) Turn/hazard light Turn switch - Testing
(Hazard light operation (A.40.A.13.83 - G.40.A.20)
okay)
All direction indicator Hazard light switch M - Hazard light switch component test
lights and hazard lights Turn/hazard light Hazard switch -
are inoperative Testing (A.40.A.13.90 - G.40.A.20)
Fuse #16 N - Direction indicator lights power supply
Fuse printed circuit circuit test Turn/hazard light - Testing
Indicator relay (A.40.A.13 - G.40.A.20)
Circuit(s)
All LH side direction Light and indicator control switch Light and indicator control switch
indicator lights Circuit(s) Open circuit between in-line harness
inoperative (Hazard light connector X148 (pin 3) and light and
operation okay) indicator control switch connector (pin 3).
All LH side direction Open in circuit 218 (PU) Open circuit between fuse printed circuit
indicator lights connector X112 (pin 3) and in-line harness
inoperative (Including connector X148 (pin 3).
LH side hazard lights)
All RH side direction Light and indicator control switch Light and indicator control switch
indicator lights Circuit(s) Open circuit between in-line harness
inoperative (Hazard light connector X148 (pin 2) and light and
operation okay) indicator control switch connector (pin 2).
All LH side direction Open in circuit 217 (PU) Open circuit between fuse printed circuit
indicator lights connector X115 (pin 3) and in-line harness
inoperative (Including connector X148 (pin 2).
LH side hazard lights)
All road lights are Fuse #20, #21 O - Road lights power supply circuit test
inoperative Fuse printed circuit Center work light - Testing (A.40.A.31 -
Light and indicator control switch G.40.A.20)
Circuit(s)
Road lights relay If test O is okay, install a new road light
relay.
All LH side road lights are Fuse #20 Check fuse #20.
inoperative Fuse printed circuit If fuse #20 is okay, install a new fuse
printed circuit.
All RH side road lights are Fuse #21 Check fuse #21.
inoperative Fuse printed circuit If fuse #21 is okay, install a new fuse
printed circuit.
Unloading tube light -
Not function (A.40.A.35 -
G.10.B.60)
Flashing beacon(s) Fuse #15, #9 R - Flashing beacon(s) circuit test Beacon
inoperative (All switch Cab roof printed circuit - Testing (A.40.A.15 - G.40.A.20)
positions) Circuit(s)
Flashing beacon(s) Flashing beacon switch S - Flashing beacon switch component test
inoperative (On-Road Beacon Switch - Testing (A.40.A.15.83 -
switch position) G.40.A.20)
Cab roof printed circuit T - Flashing beacon(s) circuit test Beacon
Circuit(s) Wiring harness - Testing (A.40.A.15.88 -
G.40.A.20)
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Flashing beacon(s) Flashing beacon switch S - Flashing beacon switch component test
inoperative (Grain tank Beacon Switch - Testing (A.40.A.15.83 -
level warning switch G.40.A.20)
position)
Fuse #7 U - Flashing beacon(s) circuit test Beacon
Flashing beacon relay Fuse - Testing (A.40.A.15.80 - G.40.A.20)
Grain level switch
Cab roof printed circuit
Circuit(s)
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LIGHTING SYSTEM - Problem solving (A.40.A - G.40.A.30)

CS540, CS640, CS520, CS660
OPERATION
Interior lighting consists of a switchable dome light with LH door switch. The dome light has an integral switch that
can be set in the off, dome or door position.
When the dome light switch is set in the door position, the light will illuminate when the driver’s door is opened.
Unswitched power is provided to the dome light so it can be operated at any time by placing the dome light switch in
the dome position.
The dome light switch can be placed in the off position, so that the dome light will not illuminate even when the door
is opened.
Power is applied to the horn switch at all times. The horn switch is integrated in to the road light switch. When the
operator closes the horn switch contact, current flows through the horn switch to operate the horn.
TROUBLESHOOTING
Before troubleshooting the interior lighting and horn system, make sure that the following operating conditions
are met:
A. The batteries are fully charged, and all connections are clean and tight.
C. Check all connectors for full installation, loose, corroded, pushed out or bent terminals.
D. Fuses #14 and #30 are good.
CAUTION
CAUTION

Interior light is inoperative Fuse #30 A - Interior light power and ground supply
Cab roof printed circuit test.Electrical light - Testing (A.40.A.85 -
Circuits G.40.A.20)
Interior light If test A is okay, install a new interior light.
Interior light operates Door switch B - Door switch circuit test.Door, window
when turned ON, but not Interior light and windscreen - Testing (E.34.A.76 -
with door Circuits G.40.A.20)
Interior light operates with Interior light ground circuit A - Interior light power and ground supply
door, but not when turned test.Electrical light - Testing (A.40.A.85 -
ON G.40.A.20)
Interior light If test A is okay, install a new interior light.
Horn does not operate Road light switch C - Horn system circuit test.Audible alert
Horn Horn - Testing (E.50.B.84.50 - G.40.A.20)
Circuits
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Head light Wiring harness - Testing (A.40.A.11.88 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Place light switch in "main beam" 12 volts. Open circuit in fuse printed circuit.
position. If good reading, go to test point 4. Open circuit between fuse printed
Disconnect fuse #24. circuit connector X114 (pin 9) and
Check for 12 volts at fuse #24. light and indicator control switch
(PU).
Light and indicator control switch.
2 Place light switch in "OFF" position. Less than 1 ohm. Open circuit between fuse printed
Disconnect light and indicator If good reading, continue with next circuit connector X114 (pin 9) and
control switch connector X148. step. light and indicator control switch
Measure resistance between connector X148 (pin 7), circuit 210
connector X114 (pin 9) and (PU).
(PU).
3 Measure resistance between Less than 1 ohm. Open circuit between fuse printed
connector X114 (pin 9) and fuse If good reading, install a new light circuit connector X114 (pin 9) and
#24. and indicator control switch. fuse #24.
Disconnect headlight connectors If good reading, install a new fuse circuit connector X114 (pin 1) and
X66 and X67. printed circuit. headlight connector(s) X66 and
Measure resistance between the X67, circuit 023 (PU).
following:
X114 (pin 1) to X66 (pin A), circuit
023 (PU).
X114 (pin 1) to X67 (pin A), circuit
023 (PU).
Head light - Testing (A.40.A.11 - G.40.A.20)

CS540, CS640, CS520, CS660
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CAUTION
WARNING

1 Place Light Switch in "dipped beam" 12 volts. Open circuit between fuse printed
position. If good reading, go to test point 3. circuit connector X113 (pin 1) and
Disconnect the fuse printed circuit light and indicator control switch
connector X113. connector X148 (pin 4), circuit 209
Check for 12 volts at connector (PU).
X113 (pin 1). Light and indicator control switch.
Disconnect light and indicator If good reading, the dipped beam circuit connector X113 (pin 1) and
control switch connector X148. circuit(s) are okay. light and indicator control switch
Measure resistance between connector X148 (pin 4), circuit 209
connector X113 (pin 1) and (PU).
(PU).
Disconnect headlight connectors If good reading, install a new Fuse circuit connector X113 (pin 9) and
X66 and X67. Printed Circuit. headlight connector(s) X66 and
Measure resistance between the X67, circuit 022 (PU).
following:
X113 (pin 9) to X66 (pin B), circuit
022 (PU).
X113 (pin 9) to X67 (pin B), circuit
022 (PU).
Turn/hazard light Turn switch - Testing (A.40.A.13.83 - G.40.A.20)

CS540, CS640, CS520, CS660
12120 1 02/07/2004
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CAUTION
WARNING

1 Disconnect the light and indicator Less than 1 ohm. Open circuit in light and indicator
control switch connector X148. If good reading, continue with next control switch.
Place light and indicator control step.
switch in the "RH indicator" position.
2 Place light and indicator control Less than 1 ohm. Open circuit in light and indicator
switch in the "LH indicator" position. If good reading, repair open circuit control switch.
Measure between connector X148 between light and indicator control
(pin 3) and (pin 6) component side. switch connector X148 (pin 6) and
fuse printed circuit X115 (pin 9),
circuit 214 (PU).
Turn/hazard light Hazard switch - Testing (A.40.A.13.90 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Remove the hazard light switch. Less than 1 ohm. Hazard light switch.
Place the switch in the "OFF" If good reading, continue with next
position. step.
Measure between terminal 3 and 4.
2 Place the switch in the "ON" Less than 1 ohm. Hazard light switch.
position. If good reading, the hazard light
Measure between the following switch is okay.
terminals:
3 and 6
2A and 5A
2A and 5B
2A and 2B
Turn/hazard light - Testing (A.40.A.13 - G.40.A.20)

CS540, CS640, CS520, CS660
12120 1 02/07/2004
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CAUTION
WARNING

1 Disconnect the hazard light switch 12 volts. Blown Fuse #16.
connector. If good reading, continue with next Open circuit in fuse printed circuit.
Turn the key start "ON". step. Open in circuit 212 (OR).
Check for 12 volts at S54 connector
(pin 6).
2 Turn the key start "OFF". Less than 1 ohm. Open circuit between fuse printed
Disconnect the fuse printed circuit If good reading, continue with next circuit connector X111 (pin 11) and
connector X111. step. hazard light switch connector, circuit
Measure between connector X111 212 (OR).
(pin 11) and S54 connector (pin 6).
3 Disconnect fuse printed circuit Less than 1 ohm. Open circuit between fuse printed
connector X115. If good reading, continue with next circuit connector X115 (pin 9) and
Measure between the following: step. hazard switch connector (pin2A),
X115 (pin 9) and S54 (pin 2A). circuit 214 (PU) or between fuse
X115 (pin 10) and S54 (pin 3). printed circuit connector X115 (10)
and hazard light switch connector
(pin 3), circuit 276 (WT).
4 Install a new indicator relay. Operation okay. Open circuit in fuse printed circuit.
Test the system for normal
operation.
Brake light - Testing (A.40.A.14 - G.40.A.20)

CS540, CS640, CS520, CS660
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CAUTION
WARNING

1 Disconnect the foot brake switch 12 volts. Blown fuse #6.
S52 connector. If good reading, continue with next Open circuit in fuse printed circuit.
Check for 12 volts at S52 connector step. Open circuit between fuse printed
(pin 1). circuit connector X112 (pin 9) and
foot brake switch connector, circuit
110 (OR).
2 Check for a ground at S52 connector Less than 5 ohms. Open circuit between foot brake
(pin 2). If good reading, brake light circuit is switch connector and in-line harness
okay. connector X137.
Beacon Fuse - Testing (A.40.A.15.80 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the flashing beacon(s) 12 volts. Blown fuse #7.
switch S34 connector. Turn the key If good reading, go to test point 4. Grain Level Switch.
start "ON". Open in circuit 027 (OR). Open in
Operate the grain level tank switch circuit 129 (GE).
S35. Go to next test point.
Check for 12 volts at S34 connector
(pin 5B).
2 Disconnect the grain tank level 12 volts. Open circuit between grain tank
switch connector X41. If good reading, continue with next level switch connector X41 (pin 1)
Check for 12 volts at X41 (pin 1). step. and fuse printed circuit connector
X112 (pin 7), circuit 027 (OR).
Open in fuse printed circuit.
3 Operate the grain tank level switch Less than 1 ohm. Grain Tank Level Switch.
S35. If good reading, open circuit between
Measure between connector X41 grain level switch connector X41
(pin 1) and (pin 2) component side. (pin 2) and flashing beacon switch
connector (pin 5B), circuit 129 (GE).
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A.40.A / 14

4 Disconnect the cab roof printed Less than 1 ohm. Open circuit between cab roof
circuit connector X132. If good reading, continue with next printed circuit connector X132 (pin
Measure between X132 (pin 4) and step. 4) and flashing beacon switch
S35 connector (pin 5A). connector (pin 5A), circuit 402 (GE).
5 Remove the flashing beacon(s) Flashing beacon(s) operate okay. Open circuit in cab roof printed
relay K23. If good reading, the flashing circuit.
Install a fused jumper wire between beacon(s) circuit is okay.
K23 terminals (pin 3) and (pin 5).
Beacon Switch - Testing (A.40.A.15.83 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Remove the flashing beacon(s) Less than 1 ohm. Flashing beacon(s) switch.
Switch. If good reading, continue with next
Place the flashing beacon switch in step.
the "On-Road" position.
Measure between terminals 2B and
3.
2 Place the flashing beacon switch in Less than 1 ohm. Flashing beacon(s) switch.
the "Grain Level Warning" position. If good reading, the flashing
Measure between terminals 5B and beacon(s) switch is okay.
5A.
Beacon Wiring harness - Testing (A.40.A.15.88 - G.40.A.20)

CS540, CS640, CS520, CS660
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CAUTION
WARNING

1 Disconnect the flashing beacon(s) Less than 1 ohm. Open circuit between flashing
switch S34 connector. Disconnect If good reading, replace the cab roof beacon switch connector (pin
the cab roof printed circuit X132. printed circuit. 2B) and cab roof printed circuit
Measure between the following: connector X132 (pin 6), circuit 126
S34 connector (pin 3) and X132 (pin (OR).
2). Open circuit between flashing
S34 connector (pin 2B) and X132 beacon switch connector (pin 3) and
(pin 6). cab roof printed circuit connector
X132 (pin 2), circuit 401 (WT).
Beacon - Testing (A.40.A.15 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the cab roof printed 12 volts. Blown fuse #15, #9.
circuit connector X132. Turn the key If good reading, continue with next Open circuit in cab roof printed
start "ON". step. circuit.
Check for 12 volts at connector
X132 (pin 6) printed circuit side.
2 Disconnect the cab roof printed Less than 1 ohm. Open circuit between the flashing
circuit connector X132. Disconnect If good reading, continue with next beacon connector X74 (pin 1) and
the Flashing Beacon connector X74. step. cab roof printed circuit connector
Measure between connector X74 X132 (pin 3), circuit 401 (WT).
(pin 1) and connector X132 (pin 3).
3 Check for a ground at the flashing Less than 1 ohm. Open circuit between the flashing
beacon connector X74 (pin 2). If reading good, the flashing beacon beacon connector X74 (pin 2) and
circuit is okay. ground, circuit 283 (ZW).
Front work light - Testing (A.40.A.16 - G.40.A.20)

CS540, CS640, CS520, CS660
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CAUTION
WARNING

1 Remove the stubble lights relay 12 volts. Open in circuit 227 (WT).
K28. If good reading, go to test point 4. Open in circuit 280 (WT).
Turn the key start "ON". Stubble light switch.
Place work light switch in the "ON" Go to next test point.
position "2".
Place the stubble light switch in the
"ON" position.
Check for 12 volts at connector K28
(pin 1).
2 Disconnect the stubble light switch 12 volts. Open circuit between work light
connector S67. If good reading, continue with next switch connector S56 (pin 5A) and
Check for 12 volts at connector S67 step. stubble light switch connector S67
(pin 2B). (pin 2B), circuit 227 (WT).
3 Turn the key start "OFF". Less than 1 ohm. Open circuit between stubble light
Measure between connector S67 If good reading, replace the stubble switch S67 (pin 3) and stubble lights
(pin 3) and connector K28 (pin 1). light switch. relay K28 (pin 1), circuit 280 (WT).
4 Check for 12 volts at connector K28 12 volts. Open circuit in cab roof printed
(pin 5). If good reading, continue with next circuit.
step.
5 Turn the key start "OFF". Less than 1 ohm resistance. Open circuit in cab roof printed
Check for a ground at connector If good reading, continue with next circuit.
K28 (pin 2). step.
6 Disconnect cab roof printed circuit Less than 1 ohm resistance. Blown fuse #32.
X126. If good reading, stubble light Open circuit in cab roof printed
Measure between connector X126 circuit(s) are okay. circuit.
(pin 1) component side and relay
connector K28 (pin 3).
Rear work light - Testing (A.40.A.17 - G.40.A.20)

CS540, CS640, CS520, CS660
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CAUTION
WARNING

1 Disconnect the Cab Roof Printed Less than 1 ohm. Open circuit between cab roof
Circuit connector X129. If good reading, continue with next printed circuit connector X129
Place the Threshing Engagement step. (pin 6) and armrest printed circuit
Switch in the “ON" position. connector X122 (pin 19), circuit 054
Check for a ground at connector (WT).
X129 (pin 6). Open circuit in Armrest Printed
Circuit.
2 Reconnect connector X129. 12 volts. Blown Fuse #33.
Disconnect the Cab Roof Printed If good reading, continue with next Open circuit in Cab Roof Printed
Circuit connector X127. step. Circuit.
Turn the keystart “ON".
Place Work Light Switch in the “ON"
position “2".
X127 (pin 5) and (pin 7) component
side.
3 Disconnect the Rear Work Lights Less than 1 ohm. Open circuit between the rear work
connectors X164 and X165. If good reading, continue with next light connectors X164 (pin 2) and
Check for a ground at the rear work step. ground, circuit 128 (ZW) and X165
lights connectors X164 (pin 2) and (pin 2) and ground, circuit 029 (ZW).
X165 (pin 2).
4 Measure between the following: Less than 1 ohm. Open circuit between the rear work
connector X164 (pin 1) and If good reading, replace the bulbs. lights connectors X164 / X165 and
connector X127 (pin 7). cab roof printed circuit connector
connector X165 (pin 1) and X127.
connector X127 (pin 5).
5 Measure between the following: Less than 1 ohm. Open circuit between the rear work
connector X164 (pin 1) and If good reading, replace the bulbs. lights connectors X164 / X165 and
connector X127 (pin 7). cab roof printed circuit connector
connector X165 (pin 1) and X127.
Work light - Testing (A.40.A.30 - G.40.A.20)

CS540, CS640, CS520, CS660
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CAUTION
WARNING

1 Remove the work light switch. Less than 1 ohm. Work light switch.
Place the work light switch in the If good reading, continue with next
"ON" position "1". step.
Measure between terminals:
5B and 5A.
2B and 2A.
2 Place the work light switch in the Less than 1 ohm. Work light switch.
"ON" position "2". If good reading, the work light switch
Measure between terminals: is okay.
5B and 6.
2B and 3.
Work light - Testing (A.40.A.30 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the work light switch 12 volts. Blown fuse #29.
connector S56. If good reading, work light switch Open circuit in cab roof printed
Turn the key start "ON". power supply circuit is okay. circuit. Open in circuit 018 (OR).
Check for 12 volts at connector S56 Go to next test point.
(pin 5B), circuit 018 (OR).
2 Disconnect the cab roof printed 12 volts. Open in cab roof printed circuit.
circuit connector X132. If good reading, continue with next
Check for 12 volts at connector step.
X132 (pin 9) printed circuit side.
3 Turn the key start "OFF". Less than 1 ohm. Open circuit between connector
Measure resistance between If good reading, work light switch X132 (pin 9) and S56 (pin 5B),
connector X132 (pin 9) and S56 (pin power supply is okay. circuit 018 (OR).
5B), circuit 018 (OR).
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Center work light - Testing (A.40.A.31 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the cab roof printed 12 volts. Blown Fuse #51.
Place work light switch in the "ON"
position "2".
X126 (pin 8).
2 Disconnect the center work light. Less than 1 ohm. Open circuit between the center
Check for a ground at the center If good reading, continue with next work light connector and ground,
work light. step. circuit 283 (ZW).
3 Measure between the center work Less than 1 ohm. Open circuit between the center
light and connector X126 (pin 8). If good reading, replace the bulb. work light and cab roof printed circuit
(PU).
Center work light - Testing (A.40.A.31 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Remove the road lights relay K26. 12 volts. Open circuit in fuse printed circuit.
Check for 12 volts at connector K26 If good reading, continue with next
(pin 3). step.
2 Check for a ground at connector Less than 1 ohm. Open circuit in fuse printed circuit.
K26 (pin 1). If good reading, continue with next
step.
3 Place light and indicator control 12 volts. Light and indicator control switch.
switch in the "Road lights ON" If good reading, go to test point 5. Open in circuit 200 (WT). Open
position. circuit in fuse printed circuit.
Check for 12 volts at connector K26 Go to next test point.
(pin 2).
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4 Disconnect the light and indicator Less than 1 ohm. Open circuit between the fuse
control switch connector X148. If good reading, replace the light printed circuit connector X113 (pin
Measure between connector X148 and indicator control switch. 10) and light and indicator control
(pin 1) and connector K26 (pin 2). switch connector X148 (pin 1),
circuit 200 (WT).
Open circuit in fuse printed circuit.
5 Disconnect the fuse printed circuit Less than 1 ohm. Blown fuse #20, #21.
connector X113. If good reading, the road light power Open circuit in fuse printed circuit.
Measure between the following: supply circuit(s) are okay.
X113 (pin 12) and K26 (pin 5).
X113 (pin 14) and K26 (pin 5).
Inner work light - Testing (A.40.A.32 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the cab roof printed 12 volts. Blown fuse #31.
position "2".
X126 (pin 4) and (pin 7).
2 Disconnect the inner work lights. Less than 1 ohm. Open circuit between the inner work
Check for a ground at the inner work If good reading, continue with next light connectors and ground, circuit
lights. step. 283 (ZW).
3 Measure between the following: Less than 1 ohm. Open circuit between the inner work
RH inner work light and connector If good reading, replace the bulbs. lights and cab roof printed circuit
X126 (pin 7). connector X126 (pin 4) and (pin 7),
LH inner work light and connector circuits 225 (PU).
X126 (pin 4).
Middle work light - Testing (A.40.A.33 - G.40.A.20)

CS540, CS640, CS520, CS660
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CAUTION
WARNING

1 Remove the middle work lights relay 12 volts. Open in circuit 227 (WT).
K15.3. If good reading, go to test point 4. Open in circuit 434 (WT).
Turn the key start "ON". Middle work light switch.
Place work light switch in the "ON" Go to next test point.
position "2".
Place the middle work light switch in
the "ON" position.
K15.3 (pin 1).
2 Disconnect the middle work light 12 volts. Open circuit between work light
switch connector S68. If good reading, continue with next switch connector S56 (pin 5A) and
Check for 12 volts at connector S68 step. middle work light switch connector
(pin 2B). S68 (pin 2B), circuit 227 (WT).
3 Turn the key start "OFF". Less than 1 ohm. Open circuit between middle work
Measure between connector S68 If good reading, replace the middle light switch S68 (pin 3) and stubble
(pin 3) and connector K15.3 (pin 1). work light switch. lights relay K15.3 (pin 1), circuit 434
(WT).
4 Check for 12 volts at connector 12 volts. Open circuit in cab roof printed
K15.3 (pin 5). If good reading, continue with next circuit.
step.
K15.3 (pin 2). step.
6 Disconnect cab roof printed circuit Less than 1 ohm resistance. Blown fuse #55, #56.
X125. If good reading, middle work light Open circuit in cab roof printed
Measure between relay connector circuit(s) are okay. circuit.
K15.3 (pin 3) and connector X125
(pin 1) and (pin 2) component side.
Outer work light - Testing (A.40.A.34 - G.40.A.20)

CS540, CS640, CS520, CS660
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CAUTION
WARNING

1 Disconnect the cab roof printed 12 volts. Blown fuse #52, #53, #54.
position "2".
X125 (pin 3), (pin 6) and (pin 9)
component side.
2 Disconnect the outer work lights. Less than 1 ohm. Open circuit between the outer work
Check for a ground at the outer work If good reading, continue with next light connectors and ground, circuit
lights. step. 283 (ZW).
3 Disconnect the grain tank light. Less than 1 ohm. Open circuit between the grain tank
Check for a ground at the grain tank If good reading, continue with next light connector and ground, circuit
light. step. 283 (ZW).
4 Measure between the following: Less than 1 ohm. Open circuit between the outer work
RH outer work light and connector If good reading, replace the bulbs. lights and cab roof printed circuit
X125 (pin 6). connector X125 (pin 9), circuit 403
LH outer work light and connector (PU) and (pin 6), circuit 224 (PU).
X125 (pin 9).
5 Measure between the grain tank Less than 1 ohm. Open circuit between the grain tank
light and connector X125 (pin 3). If good reading, replace the bulbs. light and cab roof printed circuit
(PU).
Unloading tube light - Testing (A.40.A.35 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Remove the unloading tube light Unloading tube light operates okay. Blown fuse #30.
relay K14. If good reading, go to test point 5. Open circuit in cab roof printed
Turn the key start "ON". circuit. open in circuit 222 (PU).
Install a fused jumper wire between Open in circuit 283 (ZW).
K14 terminals (pin 3) and (pin 5). Go to next test point.
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2 Check for 12 volts at K14 terminal 12 volts. Blown fuse #30.
(5). If good reading, continue with next Open circuit in cab roof printed
step. circuit.
3 Disconnect the cab roof printed Less than 1 ohm. Open circuit between the unloading
circuit connector X127. Disconnect If good reading, continue with next tube light connector (pin 1) and cab
the unloading tube light connector. step. roof printed circuit connector X127
Measure between the unloading (pin 6), circuit 222 (PU).
tube light connector (pin 1) and
4 Check for a ground at the unloading Less than 1 ohm. Open circuit between the unloading
tube light connector (pin 2). If good reading, replace the tube light connector (pin 2) and
unloading tube bulb. ground, circuit 283 (ZW).
5 Check for a ground at K14 terminal Less than 1 ohm. Open circuit in cab roof printed
(1). If good reading, continue with next circuit.
step.
6 Place the unloading tube in the 12 volts. Cab roof printed circuit.
"OUT" position. If good reading, the unloading tube Work light switch.
Place the work light switch in the light circuit is okay. Circuit(s).
"ON" position. Go to next test point.
Check for 12 volts at K14 terminal
(2).
7 Disconnect the work light switch 12 volts. Open circuit between cab roof
S56 connector. If good reading, continue with next
printed circuit X127 (pin 3) and work
Check for 12 volts at S56 connector step. light switch (pin 2B), circuit 282
(pin 2B). (WT).
Open circuit in cab roof printed
circuit.
8 Measure between K14 terminal (2) Less than 1 ohm. Open circuit between cab roof
and S56 connector (pin 3 and 2A) If good reading, the unloading tube printed circuit X129 (pin 5) and work
light circuit is okay. light switch (pin 3 and 2A), circuit
221 (WT).
circuit.
Electrical light - Testing (A.40.A.85 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the interior light 12 volts. Blown fuse #30.
connector (pin 1) (RD). If good reading, go to test point 3. Cab roof printed circuit.
Check for 12 volts at connector (pin Open circuit between interior light
1), (RD). connector (pin 1) (RD) and cab roof
printed Circuit connector X127 (pin
9), circuit 219 (RD).
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2 Disconnect the cab roof printed Less than 1 ohm. Open circuit between interior light
circuit connector X127. If good reading and fuse #30 okay, connector (pin 1) (RD) and cab roof
Measure resistance between the Install a new cab roof printed circuit. printed circuit connector X127 (pin
interior light connector (pin 1) (RD) 9).
and connector X127 (pin 9), (RD).
3 Disconnect the interior light Less than 1 ohm. Open circuit between interior light
connector (pin 1) (ZW). If good reading, the power and connector (pin 1), circuit 435 (ZW)
Check for a ground at the interior ground circuits are okay. and ground.
light connector (pin 1), (ZW).
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Index
Beacon - Testing (A.40.A.15 - G.40.A.20) 16

CS540, CS640, CS520, CS660
Beacon Fuse - Testing (A.40.A.15.80 - G.40.A.20) 14
CS540, CS640, CS520, CS660
Beacon Switch - Testing (A.40.A.15.83 - G.40.A.20) 15
CS540, CS640, CS520, CS660
Beacon Wiring harness - Testing (A.40.A.15.88 - G.40.A.20) 15
CS540, CS640, CS520, CS660
Brake light - Testing (A.40.A.14 - G.40.A.20) 13
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Electrical light - Testing (A.40.A.85 - G.40.A.20) 24
CS540, CS640, CS520, CS660
Front work light - Testing (A.40.A.16 - G.40.A.20) 16
CS540, CS640, CS520, CS660
Head light - Testing (A.40.A.11 - G.40.A.20) 10
CS540, CS640, CS520, CS660
Head light Wiring harness - Testing (A.40.A.11.88 - G.40.A.20) 10
CS540, CS640, CS520, CS660
Inner work light - Testing (A.40.A.32 - G.40.A.20) 21
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
LIGHTING SYSTEM - Testing (A.40.A - G.40.A.20) 4
CS540, CS640, CS520, CS660
Middle work light - Testing (A.40.A.33 - G.40.A.20) 21
CS540, CS640, CS520, CS660
Outer work light - Testing (A.40.A.34 - G.40.A.20) 22
CS540, CS640, CS520, CS660
Rear work light - Testing (A.40.A.17 - G.40.A.20) 17
CS540, CS640, CS520, CS660
Turn/hazard light - Testing (A.40.A.13 - G.40.A.20) 12
CS540, CS640, CS520, CS660
Turn/hazard light Hazard switch - Testing (A.40.A.13.90 - G.40.A.20) 12
CS540, CS640, CS520, CS660
Turn/hazard light Turn switch - Testing (A.40.A.13.83 - G.40.A.20) 11
CS540, CS640, CS520, CS660
Unloading tube light - Testing (A.40.A.35 - G.40.A.20) 23
CS540, CS640, CS520, CS660
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CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
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ELECTRONIC SYSTEM - 50.A
CS540
CS640
CS520
CS660
12121 1 02/07/2004
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Contents
FUNCTIONAL DATA
ELECTRONIC SYSTEM - Logical diagram (A.50.A - C.20.B.72) 4

CS540, CS640, CS520, CS660
ELECTRONIC SYSTEM - Fault code index (A.50.A - C.40.G.10) 7
CS540, CS640, CS520, CS660
Data bus
Data bus - Overview (A.50.A.92 - C.10.A.10) 11
CS540, CS640, CS520, CS660
SERVICE
Control box
Control box - Remove (A.50.A.85 - F.10.A.10) 15
CS540, CS640, CS520, CS660
Control box - Install (A.50.A.85 - F.10.A.15) 17
CS540, CS640, CS520, CS660
Data bus
Data bus - Service instruction (A.50.A.92 - F.10.A.05) 18
CS540, CS640, CS520, CS660
DIAGNOSTIC
Control box
Control box - Bad voltage (A.50.A.85 - G.30.B.31) 22
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Audio system
Audio system - Testing (A.50.A.87 - G.40.A.20) 24
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
12121 1 02/07/2004
A.50.A / 2
CS540, CS640, CS520, CS660
Audio system - Problem solving (A.50.A.87 - G.40.A.30) 27
CS540, CS640, CS520, CS660
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DISTRIBUTION SYSTEMS - ELECTRONIC SYSTEM
ELECTRONIC SYSTEM - Logical diagram (A.50.A - C.20.B.72)

CS540, CS640, CS520, CS660
The use of electronics on complex vehicles, such as the CS combine, offer many advantages to operators and
technicians. By using computer modules, communicating with each other through a CAN Bus network to share
information, many operational and maintenance features may be added to the vehicle, without the need for
excessive or complicated wiring. Many functions may be automated for the operator, making it easier to operate the
unit, and diagnostic features may be built in to the system, to aid technicians in repairs.
However, the use of computer modules does add a new challenge to the technician’s job. Solving an electrical
problem is no longer simply the matter of following a wire until the fault is found. It is important to understand that
the electronics use software that defines how systems are to work, and controls how systems operate. When a
system fails to operate on the vehicle, it becomes necessary to look for error messages that may be indicating the
source of the problem.
In some cases, there may not be any error messages present, or those present may not appear to be related to the
functional problem. This chapter is intended to provide the logic behind how each system on the combine functions,
in order to provide an understanding of what inputs and outputs are involved with each function, and how the system
is intended to operate. When a system no longer functions properly, referring to the logic diagram for that system
may provide information on what devices could be contributing to the problem.
This chapter contains basic information on how some circuits operate, and also provides more detailed “State Flow"
diagrams, which detail exactly how the software controls any given system, and what information it requires in order
to properly perform a function.
Understanding State flow diagrams
A State flow diagram is intended to provide detailed information on how a system functions, and includes each
“state" or condition a system could be in at any time, along with an indication of what information is required to
move from one "state" to another "state".
Using the "Header reversing" diagram as an example, the circles represent the different "states" that the system
may be in, while the lines between the circles represent the actions or information required to move one state to
another. In addition, the boxes are used to indicate the specific action that is occurring.
Starting at the top of the diagram, the initial conditions have to be met, which is defined by the text as being
"threshing mode, threshing mechanism engaged". In order to change to the next state, the header engagement
switch (S16) has to be activated (S16 closed).
When this condition occurs, the reversing mechanism relay (K22) is activated, which cuts the power supply to the
header reversing mechanism switch (S81) (reversing circuit not active). To move to the next state, a specific
action of disengaging the header (S16 deactivated), will deactivate the header reversing mechanism relay (K22),
voltage is now available to the reverser circuit.
The reversing mechanism relay (K20) can now be activated by the reversing mechanism switch (S81) (the next
specific action to change the state). When activated, power is supplied to the reversing mechanism solenoid (Y10)
or activation of the electrical reversing mechanism relay (K27) (units with electrical header reverser), reversing
the rotation of the header.
When the reel variator slow switch (S20) and the reversing mechanism switch (S81) are activated (the next specific
action to change the state), power is supplied to activate the header reversing mechanism relay (K21). This
switches the power supply for the header reversing mechanism solenoid (Y10) to the header reversing mechanism
(forward) solenoid (Y12), the rotation of the header is now forward slow (units with hydraulic header reverser only).
As it may be seen from this example, a specific action from the operator must be made to control this circuit. Unless
the conditions are met for engagement, the circuit will not be activated.
In other, more complex systems, several conditions must often be met, including inputs from the operator and from
other sensors, before a system will function. In some cases, if a required input is missing, the system may not
function, or may function in a reduced capacity. These state flow diagrams should assist the technician to locate
the source of the concern if this occurs.
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VFIL04CS0105H0A 1
Header reversing
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The information in this chapter is organized into sections by major system on the combine, as follows:
Starting system; includes keystart switch, starter relay, engine protection relay, stop solenoid and warning lights.
Engine protection; includes engine protection switch, engine protection relay and stop solenoid.
Engine kill stop; includes engine protection switch, engine protection relay and stop solenoid.
Header reversing; includes reversing mechanism relays, solenoids and electrical reversing motor.
Threshing and road mode engagement protection; includes threshing mechanism engagement solenoid, unloading
tube protection relay and switch.
Threshing mechanism engagement; includes threshing mechanism switch, threshing mechanism relay, threshing
mechanism protection relay, pneumatic pressure relay, pressure switch and pressure warning lights.
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A.50.A / 6
ELECTRONIC SYSTEM - Fault code index (A.50.A - C.40.G.10)

CS540, CS640, CS520, CS660
Group 100 - Sensors (with threshing engaged)

E101 E101 - GROUNDSPEED SENSOR (B7) Sensing system Ground speed sensor - Short circuit
SHORT TO GROUND to ground (C.20.B.95.80 - G.30.B.53)
E102 E102 - GROUNDSPEED SENSOR (B7) Sensing system Ground speed sensor - Short circuit
SHORT CIRCUIT TO +VE to B+ (C.20.B.95.80 - G.30.B.54)
E103 E103 - GROUNDSPEED SENSOR (B7) OPEN Sensing system Ground speed sensor - Open circuit
CIRCUIT (C.20.B.95.80 - G.30.B.50)
E104 E104 - DRUMSPEED SENSOR (B9) SHORT Sensing system Drum speed sensor - Short circuit
TO GROUND to ground (K.40.B.95.80 - G.30.B.53)
E105 E105 - DRUMSPEED SENSOR (B9) SHORT Sensing system Drum speed sensor - Short circuit
CIRCUIT TO +VE to B+ (K.40.B.95.80 - G.30.B.54)
E106 E106 - DRUMSPEED SENSOR (B9) OPEN Sensing system Drum speed sensor - Open circuit
CIRCUIT (K.40.B.95.80 - G.30.B.50)
E107 E107 - FANSPEED SENSOR (B8) SHORT TO Sensing system Fan speed sensor - Short circuit to
GROUND ground (K.62.B.95.52 - G.30.B.53)
E108 E108 - FANSPEED SENSOR (B8) SHORT Sensing system Fan speed sensor - Short circuit to
CIRCUIT TO +VE B+ (K.62.B.95.52 - G.30.B.54)
E109 E109 - FANSPEED SENSOR (B8) OPEN Sensing system Drum speed sensor - Open circuit
CIRCUIT (K.40.B.95.80 - G.30.B.50)
E110 E110 - STRAW WALKER (B13) SENSOR Sensing system Straw walker sensor - Short circuit
SHORT TO GROUND to ground (K.42.E.95.50 - G.30.B.53)
E111 E111 - STRAW WALKER (B13) SENSOR Sensing system Straw walker sensor - Short circuit
SHORT CIRCUIT TO +VE to B+ (K.42.E.95.50 - G.30.B.54)
E112 E112 - STRAW WALKER (B13) SENSOR Sensing system Straw walker sensor - Open circuit
OPEN CIRCUIT (K.42.E.95.50 - G.30.B.50)
E113 E113 - RETURN ELEVATOR (B12) SENSOR Sensing system Tailing speed sensor - Short circuit
SHORT TO GROUND to ground (K.62.C.95.80 - G.30.B.53)
E114 E114 - RETURN ELEVATOR (B12) SENSOR Sensing system Tailing speed sensor - Short circuit
SHORT CIRCUIT TO +VE to B+ (K.62.C.95.80 - G.30.B.54)
E115 E115 - RETURN ELEVATOR (B12) SENSOR Sensing system Tailing speed sensor - Open circuit
OPEN CIRCUIT (K.62.C.95.80 - G.30.B.50)
E116 E116 - STRAW CHOPPER (B10) SENSOR Sensing system Speed sensor - Short circuit to
SHORT TO GROUND ground (K.64.C.95.80 - G.30.B.53)
E117 E117 - STRAW CHOPPER (B10) SENSOR Sensing system Speed sensor - Short circuit to B+
SHORT CIRCUIT TO +VE (K.64.C.95.80 - G.30.B.54)
E118 E118 - STRAW CHOPPER (B10) SENSOR Sensing system Speed sensor - Open circuit
E119 E119 - ROTARY SEPARATOR (B11) SENSOR Sensing system Speed sensor - Short circuit to
SHORT TO GROUND ground (K.42.C.95.50 - G.30.B.53)
E120 E120 - ROTARY SEPARATOR (B11) SENSOR Sensing system Speed sensor - Short circuit to B+
SHORT CIRCUIT TO +VE (K.42.C.95.50 - G.30.B.54)
E121 E121 - ROTARY SEPARATOR (B11) SENSOR Sensing system Speed sensor - Open circuit
E122 E122 - SWATH PLATE POSITION (B26) Sensing system Swath plate position sensor - Short
SENSOR SHORT TO GROUND circuit to ground (K.64.C.95.82 - G.30.B.53)
E123 E123 - SWATH PLATE POSITION (B26) Sensing system Swath plate position sensor - Short
SENSOR SHORT CIRCUIT TO +VE circuit to B+ (K.64.C.95.82 - G.30.B.54)
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E124 E124 - SWATH PLATE (B26) POSITION Sensing system Swath plate position sensor - Open
SENSOR OPEN CIRCUIT circuit (K.64.C.95.82 - G.30.B.50)
E125 E125 - REEL SPEED (B27) SENSOR SHORT Sensing system Speed sensor - Short circuit to
TO GROUND ground (K.25.B.95.80 - G.30.B.53)
E126 E126 - REEL SPEED (B27) SENSOR SHORT Sensing system Speed sensor - Short circuit to B+
CIRCUIT TO +VE (K.25.B.95.80 - G.30.B.54)
E127 E127 - REEL SPEED (B27) SENSOR OPEN Sensing system Speed sensor - Open circuit
CIRCUIT (K.25.B.95.80 - G.30.B.50)
Group 200 - Header Functions

E201 E201 - HEADER HEIGHT SENSOR (R2) Sensing system Height sensor - Short circuit to
SHORT TO GROUND OR OPEN CIRCUIT ground (G.10.A.95.80 - G.30.B.53)
E202 E202 - HEADER HEIGHT SENSOR (R2) Sensing system Height sensor - Short circuit to B+
SHORT CIRCUIT TO +VE (G.10.A.95.80 - G.30.B.54)
E204 E204 - HEADER PRESSURE SENSOR (B18) Sensing system Pressure sensor - Short circuit to
SHORT TO GROUND OR OPEN CIRCUIT ground (G.10.A.95.81 - G.30.B.53)
E205 E205 - HEADER PRESSURE SENSOR (B18) Sensing system Pressure sensor - Short circuit to
SHORT CIRCUIT TO +VE B+ (G.10.A.95.81 - G.30.B.54)
E231 E231 - HEADER UP (SLOW) SWITCH (S29) Command Header position switch - Short circuit to
SHORT TO GROUND OR +VE ground (G.10.A.05.80 - G.30.B.53)
E232 E232 - HEADER DOWN (SLOW) SWITCH Electronic control - Short circuit to ground
(S30) SHORT TO GROUND OR +VE (G.10.A.92 - G.30.B.53)
E233 E233 - HEADER UP/DOWN (FAST) Command Header position switch - Short circuit to
SWITCHES (S50/S51) SHORT TO GROUND ground (G.10.A.05.80 - G.30.B.53)
OR +VE
E240 E240 - AUTOMATIC HEADER HEIGHT Command Header resume switch - Short circuit to
CONTROL SWITCH (S47) SHORT TO ground (G.10.A.05.83 - G.30.B.53)
GROUND
E270 E270 - HEADER UP (Y18) PWM OUTPUT Command valve Header lift valve - Open circuit
OPEN OR SHORT CIRCUIT (G.10.A.12.20 - G.30.B.50)
E271 E271 - HEADER DOWN (Y19) PWM OUTPUT Command valve Header lift valve - Open circuit
OPEN OR SHORT CIRCUIT (G.10.A.12.20 - G.30.B.50)
E280 E280 - HEADER HEIGHT CONTROL Control valve - Open circuit (G.10.A.13 - G.30.B.50)
COMPENSATION (Y20) PWM OUTPUT OPEN
OR SHORT CIRCUIT
Group 300 - Lateral Float

E301 E301 - LEFT HAND SIDE AUTOFLOAT Sensing system Position sensor - Short circuit to
POSITION SENSOR (R8) SHORT TO ground (G.30.A.95.81 - G.30.B.53)
GROUND OR OPEN CIRCUIT
E302 E302 - LEFT HAND SIDE AUTOFLOAT Sensing system Position sensor - Short circuit to B+
POSITION SENSOR (R8) SHORT CIRCUIT (G.30.A.95.81 - G.30.B.54)
TO +VE
E304 E304 - RIGHT HAND SIDE AUTOFLOAT Sensing system Position sensor - Short circuit to
POSITION SENSOR (R9) SHORT TO ground (G.30.A.95.81 - G.30.B.53)
GROUND OR OPEN CIRCUIT
E305 E305 - RIGHT HAND SIDE AUTOFLOAT Sensing system Position sensor - Short circuit to
POSITION SENSOR (R9) SHORT CIRCUIT ground (G.30.A.95.81 - G.30.B.53)
TO +VE
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E321 E321 - LATERAL FLOAT LEFT HAND SIDE Sensing system Latfloat switch - Short circuit to
DOWN (COUNTER-CLOCKWISE) SWITCH ground (G.30.A.95.80 - G.30.B.53)
(S27) SHORT TO GROUND
E322 E322 - LATERAL FLOAT RIGHT HAND SIDE Sensing system Latfloat switch - Short circuit to
DOWN (CLOCKWISE) SWITCH (S28) SHORT ground (G.30.A.95.80 - G.30.B.53)
TO GROUND
E331 E331 - LATERAL FLOAT RIGHT HAND SIDE Command valve - Open circuit (G.30.A.12 - G.30.B.50)
UP (COUNTER-CLOCKWISE) PWM OUTPUT
OPEN OR SHORT CIRCUIT
E332 E332 - LATERAL FLOAT LEFT HAND SIDE Command valve - Open circuit (G.30.A.12 - G.30.B.50)
UP (CLOCKWISE) PWM OUTPUT OPEN OR
SHORT CIRCUIT
Group 400 - Grainloss Sensors

E401 E401 - SIEVES GRAIN LOSS SENSOR (B21) Sensing system Sieve grain loss sensor - Short
SHORT TO GROUND OR OPEN CIRCUIT circuit to ground (K.62.B.95.55 - G.30.B.53)
E402 E402 - SIEVES GRAIN LOSS SENSOR (B21) Sensing system Sieve grain loss sensor - Short
SHORT CIRCUIT TO +VE circuit to B+ (K.62.B.95.55 - G.30.B.54)
E404 E404 - STRAW WALKER GRAIN LOSS Sensing system Grain loss sensor - Short circuit to
SENSOR (B20) (LEFT HAND SIDE) SHORT ground (K.42.E.95.52 - G.30.B.53)
TO GROUND OR OPEN CIRCUIT
SENSOR (B20) (LEFT HAND SIDE) SHORT B+ (K.42.E.95.52 - G.30.B.54)
TO CIRCUIT TO +VE
SENSOR (B19) (RIGHT HAND SIDE) SHORT ground (K.42.E.95.52 - G.30.B.53)
TO GROUND OR OPEN CIRCUIT
SENSOR (B19) (RIGHT HAND SIDE) SHORT B+ (K.42.E.95.52 - G.30.B.54)
TO CIRCUIT TO +VE
Group 500 - Self-Leveling

E504 E504 - SELF-LEVELLING OVERRIDE Command Self-levelling overide switch - Short
SWITCH (S26) (LEFT HAND SIDE) SHORT circuit to ground (K.62.B.05.64 - G.30.B.53)
TO GROUND
E505 E505 - SELF-LEVELLING OVERRIDE Command Self-levelling overide switch - Short
SWITCH (S26) (RIGHT HAND SIDE) SHORT circuit to ground (K.62.B.05.64 - G.30.B.53)
TO GROUND
E506 E506 - INCLINOMETER (A2) SHORT TO Sensing system Lateral inclination sensor - Short
GROUND OR OPEN CIRCUIT circuit to ground (K.62.B.95.50 - G.30.B.53)
E507 E507 - INCLINOMETER (A2) SHORT CIRCUIT Sensing system Lateral inclination sensor - Short
TO +VE circuit to B+ (K.62.B.95.50 - G.30.B.54)
E509 E509 - SELF-LEVELLING ACTUATOR Upper sieve levelling system Command - Short
POTENTIOMETER (R1) SHORT TO GROUND circuit to ground (K.62.B.64.05 - G.30.B.53)
OR OPEN CIRCUIT
E510 E510 - SELF-LEVELLING ACTUATOR Upper sieve levelling system Command - Short
POTENTIOMETER (R1) SHORT CIRCUIT TO circuit to B+ (K.62.B.64.05 - G.30.B.54)
+VE
E521 E521 - SELF-LEVELLING ACTUATOR (M6) Upper sieve levelling system Motor - Short circuit to
OUTPUT OPEN OR SHORT CIRCUIT ground (K.62.B.64.58 - G.30.B.53)
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Group 600 - Miscellaneous

E601 E601 - ROTARY DUST SCREEN BRUSHES Rotary screen Motor - Open circuit (B.50.A.58.01 -
ACTUATOR (M14) OUTPUT OPEN OR G.30.B.50)
SHORT CIRCUIT
E612 E612 - REEL VARIATOR (M5) OUTPUT OPEN Speed regulation system - Open circuit (K.25.B.42 -
OR SHORT CIRCUIT G.30.B.50)
E613 E613 - REEL SPEED UP (FAST) SWITCH Command - Short circuit to ground (K.25.B.05 -
(S21) SHORT TO GROUND OR SHORT TO G.30.B.53)
+VE
E614 E614 - REEL SPEED DOWN (SLOW) SWITCH Sensing system - Short circuit to ground (K.25.B.95 -
(S20) SHORT TO GROUND OR SHORT TO G.30.B.53)
+VE
E630 E630 - REVERSE DRIVE SIGNAL LINE Back up alarm - Short circuit to ground (E.50.B.82 -
SHORTED TO GROUND G.30.B.53)
E640 E640 - OPERATING BATTERY VOLTAGE IS Battery - Bad voltage (A.30.A.83 - G.30.B.31)
LESS THAN 10 VOLTS OR GREATER THAN
16.8 VOLTS
E641 E641 - KEY VOLTAGE (VOLTAGE AFTER Battery - Bad voltage (A.30.A.83 - G.30.B.31)
CONTACT) IS LESS THAN 10 VOLTS OR
GREATER THAN 16.8 VOLTS
E642 E642 - 10 VOLT REFERENCE SIGNAL IS Control box - Bad voltage (A.50.A.85 - G.30.B.31)
11 VOLTS
9 VOLTS
LESS THAN 4 VOLTS OR GREATE THAN 6
VOLTS
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Data bus - Overview (A.50.A.92 - C.10.A.10)

CS540, CS640, CS520, CS660
CCM module (A8) A-post module (A25)

A-post module connector (X4) Diagnostic plug (X35)
Fuse printed circuit connector (X114) CCM module connector (X141)
CAN NETWORK
The CAN network is a multiplex system which follows the guidelines established in SAE J1939. Multiplexing simply
stated, is linking two or more digital devices through a network. In the past, if RPM sensor information was needed
by a tachometer, an engine controller and a transmission, all three devices would need to be hard wired to the
RPM sensor. Through the CAN Data Bus only one wire is needed. The information is then accessed through the
network by other systems that need it. Any other system on the network that does not care about RPM data
ignores the message on the network. On todays high-tech machinery, the complexity of wiring can be greatly
reduced through the use of the CAN data bus network.
The network is made up of a twisted pair of wires, identified as CAN HI (yellow) and CAN LO (green). These two
wires are used to form a “linear bus" network, in that the wires run in parallel from one end of the vehicle to the other,
and each module is connected to both wires as a “node". These two wires are connected together at each end of the
network using a 120 ohm resistor, which is known as a “termination" resistor. Because there is a 120 ohm resistor
at each end of the network, the resistance should always be 60 ohms between the CAN HI and CAN LO wires.
On the CS combine, one of these termination resistors is located in the A-post module, while the termination resistor
on the other end of the network is located in the CCM.
The CAN network signal wires have a nominal voltages of 2.5 volts. A signal causes a voltage raise of 1.5 volts on
the CAN HI (high) wire and a voltage drop of 1.5 volts on the CAN LO (low) wire. Because there are many different
signals per second, normal voltmeters only show the average voltage. For the CAN HI wires this will be around 2.7
volts and for the CAN LO wires this will be around 2.3 volts. The deviation from the nominal 2.5 volts depends on
load of the network but must be the same for the CAN HI and CAN LO.
Short circuits to ground or power, open circuits or wrong termination resistances will deform the CAN signal and
cause network errors.
NOTE: Never short a CAN wire to 12 volts because it will burn the CAN-interfaces on the Network.
Each control module connected acts as a separate “node" on the network. As a control module receives data from
sensors, switches and potentiometers, it broadcasts this information on the network for other modules to pick up and
use as needed. Each module knows which information it needs through the software programmed into it.
When the network is initially powered up (operator turns the keystart on), each module on the network sends out
a broadcast message announcing its existence, and checks for broadcast messages from other modules on the
network. After these initial messages, each control module sends out data messages as necessary. If the module
has not sent out any data messages within 5 seconds, it will send out another broadcast message announcing
its existence. This is done in order to monitor each module’s status on the network. If a certain module has not
transmitted any messages for more than 5 seconds, then the other modules on the network will generate an
alarm message indicating that the module is "offline".
NOTE: If a control module never powers up and does not broadcast its initial message, the other modules will not be
aware that it exists, and no “offline" alarm will be generated.
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ALARMS
The network is capable of diagnosing itself and generating alarm messages to the operator when problems are
detected. If a CAN network problem is detected, the A-post module will display “FAIL" and an audible alarm will be
present. The combine may continue to function when a network alarm message appears, but systems related to
that module will no longer function.
ZVE0373A 2
TROUBLESHOOTING
There are two general conditions that may cause an individual module to go “offline"; loss of module power, or
CAN-related faults.
Each module requires a power and ground supply to provide main operating power for the module; if either of these
is lost, the module will power down and will not be active on the network.
NOTE: If a control module never powers up and does not broadcast its initial message, the other modules will not be
aware that it exists, and no “offline" alarm will be generated.
There are several possible CAN-related faults that may cause a module to go offline. External problems include bad
or open connections to the CAN HI and CAN LO network wires as a result of damaged wiring. Internal problems
may include a failure of the CAN controller itself (the device that actually does the “communicating" on the network),
or the module may be “bussing off" due to excessive error messages.
Module Power and Ground Tests
1. Before continuing to test for a fault within the CAN network signal wires, the power and grounds of the modules
on the network should be tested. Refer to the power and ground chart below for the specific power and ground
sources for each module. Use a multimeter to test for continuity to ground on the ground path, and for 12 V
power on the supply wires. If the module power and ground supplies are good, but the fault is still present,
continue with Data bus - Service instruction (A.50.A.92 - F.10.A.05).
12121 1 02/07/2004
A.50.A / 12
Module Power Ground Comments

CCM
Connector X141 pin 31, Connector X141 pin 24, Refer to Data bus
Module (A8) • • •
circuit 111 (RD), (B+) circuit 112 (ZW) - Electrical schema
(A.50.A.92 - C.20.B.40).
• Connector X141 pin 32, • Connector X142 pin 16,
circuit 110 (OR), (ignition circuit 128 (ZW) • B+ power from fuse F8
B+)
• Ignition B+ power from
fuse F11 through key
switch
A-Post
• Connector X4 pin 6, circuit • Connector X4 pin 4, circuit • Refer to Data bus
Module
110 (OR), (ignition B+) 113 (ZW) - Electrical schema
(A25)
(A.50.A.92 - C.20.B.40).
• Ignition B+ power from

fuse F11 through key
switch
ZVE0126A_102 3
ZVE0021A_103 4
12121 1 02/07/2004
A.50.A / 13
ZVE0208A_104 5
ZVE0013A_105 6
ZVE0209A_106 7
NOTE: The pin number locations for connector (X142) are the same as connector (X141).
ELECTRICAL POWER SYSTEM - Electrical schematic frame 03 (A.30.A - C.20.E.03)
12121 1 02/07/2004
A.50.A / 14
Control box - Remove (A.50.A.85 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the ignition key from the contact.

2. Switch off the battery.
3. Press onto the knob (1) to open the storage drawer
(2) that is located under the Operator’s seat.
ZEIL04CS0102A0B 1
4. Lift-up to remove the drawer (2) completely.
ZEIL04CS0033A0B 2
5. Take out the CCM module (3) completely.
ZEIL04CS0034A0B 3
12121 1 02/07/2004
A.50.A / 15
6. Remove the bolt (4) to disconnect the wire from the

module.
ZEIL04CS0035A0B 4
7. To remove the connectors, remove the central Allen

screw (5).
ZEIL04CS0036A0B 5
12121 1 02/07/2004
A.50.A / 16
Control box - Install (A.50.A.85 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the connector in the right position and tighten

the Allen screw (5).
ZEIL04CS0036A0B 1
2. Install the wire and tighten with the bolt (4).
ZEIL04CS0035A0B 2
3. Place the CCM module (3) into his place.
ZEIL04CS0034A0B 3
4. Install the storage drawer (2).
ZEIL04CS0033A0B 4
12121 1 02/07/2004
A.50.A / 17
Data bus - Service instruction (A.50.A.92 - F.10.A.05)

CS540, CS640, CS520, CS660
1. To confirm whether CAN HI and CAN LO are shorted

or open and to check the termination resistors in the
modules make the following checks at the diagnostic
plug connector X35 on the B-post console. Refer
to Data bus - Electrical schema (A.50.A.92 -
C.20.B.40) for the CAN system electrical schematic.
ZVE0153A_107 1
2. Use a multi-meter to check the resistance between

the diagnostic plug connector X35 pin C and pin D.
This will quickly verify whether there is a short or
open circuit in the system.
A reading of less than 5 ohms, confirms that CAN
HI (yellow wire) is shorted to CAN LO (green wire),
continue to step 3.
A reading of 120 ohms, confirms an open circuit in
either CAN HI or CAN LO. Continue with Step 5.
A reading of 60 ohms, confirms that there are no
open circuits in the network wiring, but there is still a
possibility of a short circuit, continue to step 9.
ZVE0037A_108 2
3. Disconnect the fuse printed circuit connector X114.

Use a multi-meter to check the resistance between
connector X35 pin C and pin D.
A reading of less than 5 ohms, confirms the short
circuit is located between the diagnostic plug
connector X35 and the fuse printed circuit connector
X114. Repair or replace the harness as required.
A reading greater than 5 ohms, confirms the short
circuit is located elsewhere, continue to step 4.
ZVE0195A_109 3
12121 1 02/07/2004
A.50.A / 18

the fuse printed circuit connector X114 pin 4 and
pin 6.
A reading of less than 5 ohms, confirms the
short circuit is located between the CCM module
connector X141 and the A-post module connector
X4. Repair or replace the harness a required.
A reading greater than 5 ohms, confirms the short
is located in the fuse printed circuit. Remove and
replace the fuse printed circuit.
ZVE0073A_110 4
5. Disconnect the CCM connector X141. Use a

multi-meter to check the resistance between the
diagnostic plug connector X35 pin C and pin D.
A reading greater than 120 ohms, confirms a faulty
A-post module termination resistor or an open circuit
between the A-post module connector X4 and the
fuse printed circuit connector X114, continue to step
6.
A reading of 120 ohms, confirms a faulty CCM
termination resistor or an open between the
CCM connector X141 and the fuse printed circuit
connector X114, continue to step 8.
ZVE0208A_111 5
6. Disconnect the A-post module connector X4,

continue to step 7.
ZVE0126A_112 6

the following diagnostic plug connector X35 and the
A-post module connector X4 pins:
X35 pin C and X4 pin 3
X35 pin D and X4 pin 2
termination resistor located in the A-post module is
faulty. Remove and replace the A-post module.
A reading greater than 5 ohms, confirms the
open circuit is located between the A-post module
connector X4 and the fuse printed circuit connector
X114. Repair or replace the harness as required.
ZVE0021A_113 7
12121 1 02/07/2004
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the following diagnostic plug connector X35 and the
CCM connector X141 pins:
X35 pin C and X141 pin 34
X35 pin D and X141 pin 35
termination resistor located in the CCM is faulty.
Remove and replace the CCM.
A reading greater than 5 ohms, confirms the open
circuit is located between the CCM connector X141
and the fuse printed circuit connector X114. Repair
or replace the harness as required.
ZVE0013A_114 8

the following diagnostic plug connector X35 pins
and ground:
X35 pin C and ground
X35 pin D and ground
A reading of less than 5 ohms, confirms a short
circuit to ground. Repair or replace the harness as
required.
A reading greater than 5 ohms, confirms no short
circuit to ground is present, continue to step 10.
ZVE0037A_108 9
12121 1 02/07/2004
A.50.A / 20
10. Turn the key start ON. Use a multi-meter to check

the voltage between following diagnostic plug
connector X35 pins and ground:
X35 pin C and ground
X35 pin D and ground
A reading greater than 0 volts, confirms a short to
power. Repair or replace the harness as required.
A reading of 0 volts, confirms the harness is okay,
continue to step 11.
11. If the fault is still present and all the wiring checks
have been carried out, CAN fault is internal to the
module. Use the Electronic Service Tool to reload
the correct version software in the module.
If the module now operates correctly, fault was due
to corrupt software. Test the system for normal
operation.
If the fault is still present after the software is
reloaded, the module has failed internally and must
be replaced to repair the fault.
12121 1 02/07/2004
A.50.A / 21
Control box - Bad voltage (A.50.A.85 - G.30.B.31)

CS540, CS640, CS520, CS660
E642 - 10 VOLT REFERENCE SIGNAL IS LESS THAN 9 VOLTS OR GREATER THAN 11 VOLTS
operation.
Cause:
Solution:
1. Check for other error codes being displayed.
A. If any other error code is being displayed, continue to these tests.
B. If no other error code is being displayed, download the correct level of software. If the fault re-occurs,
remove and replace the CCM.
12121 1 02/07/2004
A.50.A / 22

CS540, CS640, CS520, CS660
E643 - 8 VOLT REFERENCE SIGNAL IS LESS THAN 7 VOLTS OR GREATER THAN 9 VOLTS
operation.
Cause:
Solution:
12121 1 02/07/2004
A.50.A / 23

CS540, CS640, CS520, CS660
E644 - 5 VOLT REFERENCE SIGNAL IS LESS THAN 4 VOLTS OR GREATE THAN 6 VOLTS
operation.
Cause:
Solution:
Audio system - Testing (A.50.A.87 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Check for 12 volts at audio unit 12 volts Blown fuse #30.
connector X107 (pin 1). If good reading, continue with next Open circuit between audio unit
step. connector X107 (pin 1) and cab roof
printed circuit connector X127 (pin
9), circuit 219 (RD).
circuit.
2 Check for ground at audio unit Less than 1 ohm resistance. Open circuit between audio unit
connector X107 (pin 6). If good reading, the power and connector X107 (pin 6) and battery
ground circuits are okay. ground, circuit 004 (BL).

CS540, CS640, CS520, CS660
12121 1 02/07/2004
A.50.A / 24
CAUTION
WARNING

1 Measure resistance between Less than 1 ohm resistance. Bad connection between antenna
antenna cable shield to ground. If good reading, continue with next base and body.
step. Open circuit in antenna cable shield.
2 Measure resistance between Less than 1 ohm resistance. Open circuit in antenna cable.
antenna cable center terminal and If good reading, continue with next
antenna base center terminal. step.
3 Measure resistance between Open circuit. Short circuit between the antenna
antenna cable center terminal and If good reading, antenna cable is cable center terminal and shield.
antenna cable shield. okay.

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the suspect speaker. Between 4 - 8 ohms. Open/short circuit in speaker.
Measure the resistance between If good reading, the speaker is okay.
terminals 1 and 2 of the speaker.

CS540, CS640, CS520, CS660
12121 1 02/07/2004
A.50.A / 25
CAUTION
WARNING

1 Disconnect the audio unit and Less than 1 ohm resistance. Open circuit in speaker circuit 234
left-hand speaker. If good reading, continue with next (BR).
Measure resistance between audio step.
unit connector X107 (pin 2) and
speaker connector, circuit 234 (BR).
2 Measure resistance between audio Less than 1 ohm resistance. Open circuit in speaker circuit 233
unit connector X107 (pin 4) and If good reading, continue with next (BL).
speaker connector, circuit 233 (BL). step.
3 Measure resistance between audio Open circuit. Short to ground in circuit 234 (BR)
unit connector X107 (pin 2) and If good reading, left hand speaker or 233 (BL).
ground and between (pin 4) and wiring is okay.
ground.

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the audio unit and Less than 1 ohm resistance. Open circuit in speaker circuit 232
right-hand speaker. If good reading, continue with next (BR).
Measure resistance between audio step.
unit connector X107 (pin 3) and
speaker connector, circuit 232 (BR).
2 Measure resistance between audio Less than 1 ohm resistance. Open circuit in speaker circuit 231
unit connector X107 (pin 5) and If good reading, continue with next (BL).
speaker connector, circuit 231 (BL). step.
3 Measure resistance between audio Open circuit. Short to ground in circuit 232 (BR)
unit connector X107 (pin 3) and If good reading, right-hand speaker or 231 (BL).
ground and between (pin 5) and wiring is okay.
ground.
12121 1 02/07/2004
A.50.A / 26
Audio system - Problem solving (A.50.A.87 - G.40.A.30)

CS540, CS640, CS520, CS660
OPERATION
The audio system does not come standard, but is designed to incorporate two speakers and a stereo unit.
TROUBLESHOOTING
Before troubleshooting the Audio system make sure that the following operating conditions are met:
D. Check Fuses 14 and 30.
CAUTION
CAUTION

Audio system - Not
function (A.50.A.87 -
G.10.B.60)
Poor reception Antenna B - Antenna Test Audio system - Testing
(A.50.A.87 - G.40.A.20)
Antenna cable B - Antenna Test Audio system - Testing
(A.50.A.87 - G.40.A.20)
Audio Unit If Test B is okay, Install a new audio unit.
Poor quality / distorted Speaker(s) C - Speaker resistance test.Audio system
sound from one or more - Testing (A.50.A.87 - G.40.A.20)
speakers
Circuit(s) D - Speaker circuit test (left hand
side)Audio system - Testing (A.50.A.87 -
G.40.A.20)
Circuit(s) E - Speaker circuit test (right hand
side)Audio system - Testing (A.50.A.87 -
G.40.A.20)
Audio Unit If Test(s) C, D and E are okay, Install a
new audio unit.
Audio system - Not
function (A.50.A.87 -
G.10.B.60)
Audio operates, tape Audio unit Install a new audio unit
player does not operate
12121 1 02/07/2004
A.50.A / 27
Index
Audio system - Problem solving (A.50.A.87 - G.40.A.30) 27

CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Control box - Install (A.50.A.85 - F.10.A.15) 17
CS540, CS640, CS520, CS660
Control box - Remove (A.50.A.85 - F.10.A.10) 15
CS540, CS640, CS520, CS660
Data bus - Overview (A.50.A.92 - C.10.A.10) 11
CS540, CS640, CS520, CS660
Data bus - Service instruction (A.50.A.92 - F.10.A.05) 18
CS540, CS640, CS520, CS660
ELECTRONIC SYSTEM - Fault code index (A.50.A - C.40.G.10) 7
CS540, CS640, CS520, CS660
ELECTRONIC SYSTEM - Logical diagram (A.50.A - C.20.B.72) 4
CS540, CS640, CS520, CS660
12121 1 02/07/2004
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12121 1 02/07/2004
A.50.A / 29
NEW HOLLAND BELGIUM N.V., Leon Claeystraat 3A, B-8210 ZEDELGEM - Belgium
SERVICE - Technical Publications & Tools
PRINTED IN BELGIUM
COPYRIGHT BY NEW HOLLAND BELGIUM N.V.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
New Holland policy is one of continuous improvement and the right to change prices, specification or equipement
at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your New Holland Dealer.
12116 1 02/07/2004
REPAIR MANUAL
POWER PRODUCTION
CS540
CS640
CS520
CS660
12122 1 02/07/2004
B
Contents
ENGINE B.10.A
CS540, CS640, CS520, CS660
FUEL AND INJECTION SYSTEM B.20.A

CS540, CS640, CS520, CS660
ENGINE COOLANT SYSTEM B.50.A

CS540, CS640, CS520, CS660
LUBRICATION SYSTEM B.60.A

CS540, CS640, CS520, CS660
STARTING SYSTEM B.80.A

CS540, CS640, CS520, CS660
12122 1 02/07/2004
B
ENGINE - 10.A
CS540
CS640
CS520
CS660
12123 1 02/07/2004
B.10.A / 1
Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE - Torque (B.10.A - D.20.A.10) 5

CS540, CS640, CS520, CS660
ENGINE - Special tools (B.10.A - D.20.A.40) 6
CS540, CS640, CS520, CS660
ENGINE - General specification (B.10.A - D.40.A.10) 7
CS540, CS640, CS520, CS660
Crankshaft
Crankshaft - General specification (B.10.A.43 - D.40.A.10) 8
CS540, CS640, CS520, CS660
Connecting rod and piston

Connecting rod and piston - General specification (B.10.A.47 - D.40.A.10) 10
CS540, CS640, CS520, CS660
Cylinder head
Cylinder head - General specification (B.10.A.72 - D.40.A.10) 10
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
ENGINE - Static description (B.10.A - C.30.A.20) 13

CS540, CS640, CS520, CS660

Connecting rod and piston - Exploded view (B.10.A.47 - C.10.A.20) 17
CS540, CS640, CS520, CS660
Electronic control
Electronic control - Logical diagram (B.10.A.92 - C.20.B.72) 18
CS540, CS640, CS520, CS660
SERVICE
ENGINE - Overhaul (B.10.A - F.10.A.40) 20

CS540, CS640, CS520, CS660
ENGINE - Compression test (B.10.A - F.40.A.35) 21
CS540, CS640, CS520, CS660
Valve drive
Valve drive Camshaft - Remove (B.10.A.40.44 - F.10.A.10) 22
CS540, CS640, CS520, CS660
Valve drive Camshaft - Overhaul (B.10.A.40.44 - F.10.A.40) 24
CS540, CS640, CS520, CS660
Valve drive Camshaft - Install (B.10.A.40.44 - F.10.A.15) 25
CS540, CS640, CS520, CS660
12123 1 02/07/2004
B.10.A / 2
Valve drive - Overhaul (B.10.A.40 - F.10.A.40) 27
CS540, CS640, CS520, CS660
Crankshaft
Crankshaft Front seal - Remove (B.10.A.43.01 - F.10.A.10) 31
CS540, CS640, CS520, CS660
Crankshaft - Remove (B.10.A.43 - F.10.A.10) 32
CS540, CS640, CS520, CS660
Crankshaft - Install (B.10.A.43 - F.10.A.15) 33
CS540, CS640, CS520, CS660
Crankshaft Front seal - Install (B.10.A.43.01 - F.10.A.15) 36
CS540, CS640, CS520, CS660
Crankshaft - Overhaul (B.10.A.43 - F.10.A.40) 38
CS540, CS640, CS520, CS660
Timing gear
Timing gear - Remove (B.10.A.45 - F.10.A.10) 40
CS540, CS640, CS520, CS660
Timing gear - Install (B.10.A.45 - F.10.A.15) 43
CS540, CS640, CS520, CS660

Connecting rod and piston - Remove (B.10.A.47 - F.10.A.10) 45
CS540, CS640, CS520, CS660
Connecting rod and piston - Overhaul (B.10.A.47 - F.10.A.40) 46
CS540, CS640, CS520, CS660
Connecting rod and piston - Install (B.10.A.47 - F.10.A.15) 48
CS540, CS640, CS520, CS660
Flywheel
Flywheel - Remove (B.10.A.50 - F.10.A.10) 49
CS540, CS640, CS520, CS660
Flywheel - Install (B.10.A.50 - F.10.A.15) 50
CS540, CS640, CS520, CS660
Cylinder block
Cylinder block - Overhaul (B.10.A.70 - F.10.A.40) 51
CS540, CS640, CS520, CS660
Cylinder block - Rebore (B.10.A.70 - F.75.C.30) 53
CS540, CS640, CS520, CS660
Cylinder block - Assemble (B.10.A.70 - F.10.A.20) 54
CS540, CS640, CS520, CS660
Cylinder head
Cylinder head - Remove (B.10.A.72 - F.10.A.10) 56
CS540, CS640, CS520, CS660
Cylinder head - Disassemble (B.10.A.72 - F.10.A.25) 59
CS540, CS640, CS520, CS660
Cylinder head - Overhaul (B.10.A.72 - F.10.A.40) 60
CS540, CS640, CS520, CS660
Cylinder head - Assemble (B.10.A.72 - F.10.A.20) 61
CS540, CS640, CS520, CS660
Rear cover
Rear cover - Remove (B.10.A.76 - F.10.A.10) 65
CS540, CS640, CS520, CS660
Rear cover - Install (B.10.A.76 - F.10.A.15) 66
CS540, CS640, CS520, CS660
DIAGNOSTIC
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B.10.A / 3
ENGINE - Troubleshooting (B.10.A - G.40.A.10) 68
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
12123 1 02/07/2004
B.10.A / 4
POWER PRODUCTION - ENGINE
ENGINE - Torque (B.10.A - D.20.A.10)

CS540, CS640, CS520, CS660
TORQUE VALUES - VARIOUS Nm lb.ft

Main bearing bolts 81 + 90 ° 60 + 90 °
Connecting rod bolts 149 110
Cylinder head bolts (with engine cold) 55-95+90 ° 40-70+90 °
Cylinder head through rocker shaft bolts As above +45 ° As above +45 °
Intake manifold-to-cylinder head 35 26
Exhaust manifold-to-cylinder head 61 45
Exhaust pipe-to-flange 31 23
Flywheel-to-crankshaft 197 145
Oil pan drain plug 41 30
Valve rocker cover bolts 24 18
Crankshaft pulley-to-crankshaft 224 210
Self-locking screw - Valve rocker arm 24 18
Injector attachment bolts 23 17
Cover bolts (Blanks oil drilling) 31 23
Oil pump to block 23 17
Water pump-to-cylinder block 35 48
Water pump cover-to-pump 27 20
Oil pan-to-cylinder block 44 33
Injector line nuts 24 18
Leak-off tube banjo fitting bolts 6 4.4
Injection pump-to-front cover 24 18
Camshaft idler drive gear-to-block 237 175
Front cover-to-cylinder block 24 18
Thermostat housing bolts 24 18
Camshaft gear bolt 69 51
Camshaft rear gear plate bolts 47 35
Oil filter adaptor bolts 42 31
Oil filter mounting bolt insert 34 25
Starting motor-to-rear adaptor plate 31 23
Injection pump-to-gear nut 92 68
Oil pressure switch assembly 31 23
Turbocharger-to-exhaust manifold nut 44 33
Fan blade to viscous unit 27 21
Viscous unit to pulley 54 40
Crankshaft rear oil seal retainer 20 15
Belt tensioner pulley bolt 54 40
Temperature senders 20 15
Tensioner to water pump bolt 54 40
Idler pulley bolt 54 40
Pump connector to block 24 18
The following general nut and bolt installation torque requirements (lubricated) apply to any operation not previously
listed.
12123 1 02/07/2004
B.10.A / 5
INCH SERIES Nm lb.ft

1/4 - 20 11 8
1/4 - 28 11 8
5/16 -18 19 14
5/16 -24 23 17
3/4 - 16 31 23
3/4 - 24 45 33
7/16 -14 65 48
7/16 -20 75 55
1/ - 13 88 65
1/2 - 20 102 75
9/16 -18 122 90
5/6 -18 187 138
CYLINDER BLOCK PLUGS
1/4 - 27 NPT 11 8
1/4 - 18 NPT 29.8 22
3/4 - 18 NPT 38 28
3/4 - 14 NPT 27 20
ENGINE - Special tools (B.10.A - D.20.A.40)

CS540, CS640, CS520, CS660
10_2-23_01 1
Fuel injection pump drive gear puller (Local manufacture or Special tool no.380000322 (295042)
1. Bolt 5/16-UNF x 2 in. (51 mm) with integral washer (3 bolts required)
2. Bolt 3/4x16-UNC x 2 in.(51 mm)
3. Three holes 0.375 in (9.5 mm) dia. on 2.2 in (56.87 mm) dia.
equally spaced material of 0.394 in. (10 mm) Plate HRLC P&O Steel
(Prior tool numbers, where applicable, shown in brackets)
Description CNH number (ex) NH number

Engine sling hook, (use with brackets 380000216 290740
50075 and 50076)
Engine revolving stand 380000301 290090
Engine overhaul brackets kit 380000313 293860
Cylinder pressure test kit 380000303 291309 & 295039
Lube pressure check kit 380000240 292870
12123 1 02/07/2004
B.10.A / 6

Piston ring pliers 380000324 296028
Piston install band 380000325 296042
Crankshaft rear seal installer 380000332 297252 or 297194
Crankshaft front seal puller - 297670
Crankshaft front seal installer 380000455 297115
Valve guide set reamers 380000319 295006
Valve spring compressor 380000302 291050
Water pump impeller seal installer - 295007
Injector - hand pump tester - 290284
Injector - cleaning kit 380000254 293671
Injector - splitting block 380000308 293760
Injector - splitting socket kit 380000309 293761
Injection pump drive gear puller 380000322 295042
Adjustable bridge puller 380000329 297102
Shaft protector - 297107
Step plate adaptors - -
Bushing kit - -
Camshaft bearing installer 380000331 297117
Handle (for camshaft bearing installer) - 291896
Crankshaft timing pin 380000172 297672
Fuel Injection pump timing pin 380000318 295005

CS540, CS640, CS520, CS660
Governor mechanical
Rated speed 2100 rpm
Low idle speed 1300 rpm
High idle speed 2205 rpm
Cylinder displacement 7500 cc (458 cu. in.)
Bore 112 mm (4.4 in.)
Stroke 127 mm (5.0 in.)
Compression ratio 17.0 - 1
Cylinder bore Compression at cranking speed of 25.5 bar (375 psi)
200 RPM
Water pump speed 3859 rpm
Ventilator speed 1530 rpm
Crankcase capacity (with filters) 23 liters
Alternator type 135 Ampère (12 Volt)
Alternator speed 5426 rpm
Starter motor 4.5 kW (12 Volt)
Air conditioning compressor speed 3616 rpm
CYLINDER BLOCK
12123 1 02/07/2004
B.10.A / 7
Taper of cylinder bore 0.025 mm (0.001 in ) repair limit

0.127 mm (0.005 in ) wear limit
Cylinder bore out of round 0.030 mm (0.0015 in) repair limit
0.127 mm (0.0050 in) wear limit
Cylinder bore diameters 111.778-111.803 mm (4.4007-4.4017 in)
Rear oil seal bore diameter 140.77-140.87 mm (5.542-5.546 in)
Block to head surface flatness 0.08 mm (0.003 in) in any 152 mm (6 in)
0.03 mm (0.001 in) in any 25.40 mm (1 in)
Crankshaft - General specification (B.10.A.43 - D.40.A.10)

CS540, CS640, CS520, CS660
CRANKSHAFT
Main journal diameter - Blue 85.631-85.644 mm (3.3713-3.3718 in)

Main journal diameter - Red 85.644-85.656 mm (3.3718-3.3723 in)
Main journal length (except thrust, rear, or 36.96-37.21 mm (1.455-1.465 in)
intermediate)
Main journal wear limits 0.127 mm (0.005 in) Maximum
Main and crank pin fillet radius 0.25 mm (0.010 in)
Thrust bearing journal length 37.06-37.11 mm (1.459-1.461 in)
Intermediate bearing journal length 36.96-37.21 mm (1.455-1.465 in)
Rear bearing journal length 37.97-38.48 mm (1.495-1.515 in)
Crank pin journal length 42.62-42.72 mm (1.678-1.682 in)
Crank pin diameter - Blue 69.840-69.850 mm (2.749-2.7500 in)
Crank pin diameter - Red 69.850-69.860 mm (2.750-2.7504 in)
End play 0.10-0.36 mm (0.004-0.014 in)
Crank pin out of round 0.005 mm (0.0002 in) Total Indicator Reading
Taper surface parallel to centre line of main journal 0.005 mm (0.0002 in)
Crankshaft rear oil seal journal diameter 122.12-122.28 mm (4.808-4.814 in)
Crankshaft pulley journal diameter 51.788-51.808 mm (2.0389-2.0397 in)
Crankshaft timing gear journal diameter 52.131-52.146 mm (2.0524-2.0530 in)
Crankshaft flange runout 0.038 mm (0.0015 in) Max
CRANKSHAFT DRIVE GEAR
Number of teeth 26
MAIN BEARING
Liner length (except thrust liner) 27.94-28.19 mm (1.10-1.11 in)

Liner length (thrust liner) 39.91-39.96 mm (1.453-1.455 in)
Vertical assembled bearing clearance 0.055-0.117 mm (0.0021-0.0046 in)
CRANK PIN BEARINGS
Liner length 31.5-31.75 mm (1.240-1.250 in)

Vertical assembled bearing clearance 0.038-0.104 mm (0.0015-0.0041 in)
Bearing clearance - Service limit 0.127 mm (0.005 in)
CRANKSHAFT REGRINDING
When regrinding a crankshaft the main and crank pin journal diameters should be reduced the same amount as
the under size bearings used, and the following dimensions apply. The rear end of the crankshaft should be
located on the 60 ° Chamfer of the pilot bearing bore.
12123 1 02/07/2004
B.10.A / 8
UNDER SIZE BEARING AVAILABLE MAIN JOURNAL DIAMETERS

0.051 mm (0.002 in) 85.580-85.593 mm (3.3693-3.3698 in)
0.254 mm (0.010 in) 85.390-85.402 mm (3.3618-3.3623 in)
0.508 mm (0.020 in) 85.136-85.148 mm (3.3518-3.3523 in)
0.762 mm (0.030 in) 84.882-84.894 mm (3.3418-3.3423 in)
1.016 mm (0.040 in) 4.628-84.640 mm (3.3318-3.3323 in)
12123 1 02/07/2004
B.10.A / 9
UNDER SIZE BEARING AVAILABLE CRANK PIN JOURNAL DIAMETERS

0.051 mm (0.002 in) 69.789-69.799 mm (2.7476-2.7480 in)
.254 mm (0.010 in) 69.956-69.606 mm (2.7400-2.7404 in)
0.508 mm (0.020 in) 69.342-69.352 mm (2.7300-2.7304 in)
0.762 mm (0.030 in) 69.088-69.098 mm (2.7200-2.7204 in)
1.016 mm (0.040 in) 68.834-68.844 mm (2.7100-2.7104 in)
FLYWHEEL
Runout of clutch face ( Between outer edge of 0.127 mm (0.005 in)

friction surface and mounting bolt holes),
Ring gear runout 0.63 mm (0.025 in)
Connecting rod and piston - General specification (B.10.A.47 -

D.40.A.10)
CS540, CS640, CS520, CS660
CONNECTING RODS
Small end bushing (internal diameter) 44.460-44.467 mm (1.7504-1.7507)

Big end bearing clearance 0.038-0.104 mm (0.0015-0.0041 in)
Clearance bushing to piston pin 0.013-0.025 mm (0.0005-0.0010 in)
Side float 0.13-0.33 mm (0.0050-0.0130 in)
Maximum twist 0.30 mm (0.0120 in)
Maximum bend 0.10 mm (0.0040 in)
PISTON PIN
Outside diameter 44.442-44.447 mm (1.7497-1.7499 in)

PISTONS
Skirt to cylinder clearance 0.152-0.182 mm (0.0060-0.0072 in) New or unrun engine

Taper (out of round) 0.063-0.127 mm (0.0025-0.0050 in)
Grading diameter (at right angles to Piston pin) 111.64-111.74 mm (4.3951-4.3991 in) in increments of 0.0127
mm (0.0005 in)
Piston pin clearance 0.0127-0.0254 mm (0.0005-0.0001 in) at 21 °C (70 °F)
Piston crown to block face, 0.005-0.015 mm (0.13-0.38 in
PISTON RINGS
Top compression ring Keystone tapered sides with letter "O" to the top
2nd compression ring Parallel side external step
Side face clearance to ring groove 0.06-0.105 mm (0.0023-0.0041 in)
Piston groove width 2.435-2.455 mm (0.0959-0.0967 in)
Oil control ring 1 off,-Directly above the piston pin,
Type Slotted with expander
Side face clearance to ring groove 0.030-0.070 mm (0.0011-0.0028 in)
Piston groove width 3.02-3.04 mm (0.1189-0.1197 in)
Cylinder head - General specification (B.10.A.72 - D.40.A.10)

CS540, CS640, CS520, CS660
CYLINDER HEAD
12123 1 02/07/2004
B.10.A / 10
Valve guide bore diameter 9.469-9.495 mm (0.3728-0.3738 in)

Head to block surface flatness 0.03 mm (0.001 in) in any 25.40 mm (1 in),
or 0.127 mm (0.005 in) overall limit
EXHAUST VALVES
Face angle 44 °15 ’-44 °30 ’ Relative to the head of valve

Stem diameter Std : 9.401-9.421 mm (0.3701-0.3709 in)
Oversize : 0.38 mm (0.015 in)
9.781-9.802 mm (0.3851-0.3859 in)
Head diameter 42.88-43.13 mm (1.688-1.698 in)
Stem to guide clearance 0.048-0.094 mm (0.0019-0.0037 in)
Lash clearance (cold) 0.43-0.53 mm (0.017-0.021 in)
INTAKE VALVES
Face angle 29 °15 ’-29 °30 ’ Relative to head of valve

Stem diameter Std : 9.426-9.446 mm (0.3711-0.3719 in)
Oversize : 0.381 mm (0.015 in)
9.807-9.827 mm (0.3861-0.3869 in)
Head diameter 47.37-47.63 mm (1.865-1.875 in)
Stem to guide clearance 0.023-0.069 mm (0.0009-0.0027 in)
Lash clearance (cold) 0.36-0.46 mm (0.014-0.018 in)
VALVE SPRINGS
Number per valve 1

Free length 60.70 mm (2.390 in)
Length, loaded at 27.7-31.3 kg (61-69 lb) 48.26 mm (1.900 in)
Length, loaded at 61-69 kg (135-153 lb) 35.69 mm (1.405 in)
CAMSHAFT LOBE LIFT
Intake 8.36 mm (0.330 in)

Exhaust 8.36 mm (0.330 in)
INSTALLED VALVE RECESSION
Intake 0.86-1.32 mm (0.034-0.052 in)

Exhaust. 1.17-1.65 mm (0.046-0.065 in)
Valve inserts
Exhaust valve insertCounter bore Intake valve seat insertCounter bore

Insert oversize diameter in cylinder head diameter in cylinder head
0.254 mm (0.010 in) 44.17-44.20 mm (1.739-1.740 in) 50.01-50.04 mm (1.969-1.970 in)
0.508 mm (0.020 in) 44.42-44.45 mm (1.749-1.750 in) 50.27-50.29 mm (1.979-1.980 in)
0.762 mm (0.030 in) 44.68-44.70 mm (1.759-1.760 in) 50.52-50.55 mm (1.989-1.990 in)
12123 1 02/07/2004
B.10.A / 11
VALVE SEATS
Exhaust valve seat angle 45 °00 ’ - 45 °30 ’

Intake valve seat angle 30 °00 ’ - 30 °30 ’
Interference valve face angle to valve seat angle 0 °30 ’ - 1 °15 ’
Concentricity with guide Diameter .051 mm (0.002 in) Total Indicator Reading Max
Seat width Exhaust valve 1.8-2.3 mm (0.072-0.092 in)
Intake valve
1.9-2.5 mm (0.078-0.098 in)
CAMSHAFT IDLER GEAR
Number of teeth 47
End play 0.076-0.35 mm (0.003-0.014 in)
Bushing inside diameter 50.813-50.838 mm (2.005-2.0015 in)
Adaptor outside diameter 50.762-50.775 mm (1.9985-1.9990 in)
Backlash with crankshaft gear 0.10-0.36 mm (0.004-0.014 in)
Backlash with camshaft gear 0.10-0.36 mm (0.004-0.014 in)
Backlash with fuel injection pump 0.10-0.48 mm (0.004-0.019 in)
CAMSHAFT GEAR
Number of teeth 52
Timing gear backlash with idler 0.10-0.36 mm (0.004-0.014 in)
ROCKER ARM SHAFT
Shaft diameter 25.40-25.43 mm (1.000-1.001 in)

Shaft support internal diameter 25.45-25.20 mm (1.002-1.004 in)
ROCKER ARM
Inside diameter 25.48-25.50 mm (1.003-1.004 in)

TAPPETS
Clearance to bor 0.015-0.058 mm (0.0006-0.0023 in)

Tappet diameter 25.113-25.131 mm (0.9889-0.9894 in)
Tappet bore diameter 25.146-25.171 mm (0.9900-0.9910 in)
CAMSHAFT
Bearing journal diameter 60.642-60.668 mm (2.3875-2.3885 in)

Bearing clearance 0.076-0.178 mm (0.003-0.007 in)
End play 0.051-0.18 mm (0.0020-0.0070 in)
12123 1 02/07/2004
B.10.A / 12
ENGINE - Static description (B.10.A - C.30.A.20)

CS540, CS640, CS520, CS660
10_2-23_02 1
The CNH 7.5 Liter engine is a 6-cylinder turbocharged and after cooled, having a bore of 111.8 mm (4.4 in) and a
stroke of 127 mm (5.0 in) which generates a displacement of 7.5 L (456 in3).
The engine uses a mechanical controlled in line injection pump 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 refer to FUEL AND INJECTION SYSTEM - Static description (B.20.A - C.30.A.20).
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.
12123 1 02/07/2004
B.10.A / 13
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.
10_2-23_03 2
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 3
12123 1 02/07/2004
B.10.A / 14
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.
P396-E-2 4
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.
10_2-23_06 5
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.
BSD1856A 6
12123 1 02/07/2004
B.10.A / 15
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.
P396-E-32 7
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.
P396E-36 8
12123 1 02/07/2004
B.10.A / 16
Connecting rod and piston - Exploded view (B.10.A.47 - C.10.A.20)

CS540, CS640, CS520, CS660
BSD1858A 1
Piston assembly
1 Con rod 2 Piston

3 Piston pin 4 Retainer
5 Piston ring (Compression) 6 Piston ring (Compression)
7 Piston ring (Oil Control) 8 Bolt
9 Bearing cap 10 Bearing liner
11 Bearing liner 12 Bush
12123 1 02/07/2004
B.10.A / 17
Electronic control - Logical diagram (B.10.A.92 - C.20.B.72)

CS540, CS640, CS520, CS660
07_11_14_02 1
ENGINE PROTECTION
12123 1 02/07/2004
B.10.A / 18
ENGINE PROTECTION FIGURE KEY

K3 ENGINE PROTECTION RELAY
K4 ENGINE PROTECTION RESET RELAY
S9 ENGINE PROTECTION RESET + KILL STOP SWITCH
Y3 ENGINE STOP SOLENOID
Initial conditions:
The key start (S3) must be switched on, the start protection switch (S2) in the off (open) position and the engine
running under normal operating conditions (warning detection signal high).
When the initial conditions are met and a concern is detected (warning signal low), the warning buzzer and warning
lights are activated. The engine protection relay (K3) is activated, which cuts power to the engine stop solenoid (Y3)
hold coil, stopping the engine.
When the engine protection switch (S9) is activated (short pulse)
The buzzer and warning lights are deactivated (if a failure is still present the warning light will remain activated).
A ground is supplied to the engine protection reset relay (K4), activating it. This cuts the ground circuit of the
engine protection relay (K3), deactivating it. The engine stop solenoid (Y3) pull coil activates and the engine
is able to re-start.
When the engine protection switch (S9) is not activated.
With the key start still in position 1, the engine will be unable to start, due to the failure still being present.
Refer to ELECTRICAL POWER SYSTEM - Electrical schematic frame 01 (A.30.A - C.20.E.01)
12123 1 02/07/2004
B.10.A / 19
ENGINE - Overhaul (B.10.A - F.10.A.40)

CS540, CS640, CS520, CS660
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.
Dismantle the engine following conventional techniques and by referring to the appropriate overhaul sections of this
chapter. Always refer to ENGINE - General specification (B.10.A - D.40.A.10) as necessary.
For concerns relating to the fuel system refer to FUEL AND INJECTION SYSTEM - Static description (B.20.A -
C.30.A.20)
NOTE: All gaskets, seals, and O-rings must be replaced during reassembly. Where new sealant is to be applied
refer to ENGINE - General specification (B.10.A - D.40.A.10).
1. Operations or repairs that can be performed with
the engine still in the vehicle.
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.
12123 1 02/07/2004
B.10.A / 20
ENGINE - Compression test (B.10.A - F.40.A.35)

CS540, CS640, CS520, CS660
TEST PROCEDURE :
1. Be sure battery performance meets specifications.

2. Warm up the engine by operating for a minimum of
half an hour at 1200 rpm.
3. Stop the engine and remove the injector and seat
washer from no1 cylinder.
4. Clean the injector bore and crank the engine to blow
out any loose carbon particles.
5. Install an engine compression test gauge, From
kit No.291309 with fault injector 295039, into the
injector bore, using a new seat washer and the
injector mounting bolts.
6. Connect the gauge and hose to the adapter.
7. Crank the engine at 200 rpm with the electric fuel
shut off wire disconnected to prevent engine start
up.
8. Observe the gauge reading, and repeat the
compression test, steps 5-7 for each cylinder.
TEST READINGS :
9. All cylinder compressions should be uniformly within
1.7 bar (25 psi) of each other.
10. A reading of more than the 1.7 bar (25 psi) below
the other cylinders indicates leakage at the cylinder
head gasket, piston rings or valves.
11. A reading of more than 1.7 bar (25 psi) above the
other cylinders indicates excessive carbon deposits
on the piston and cylinder head.
12. A low even compression in two adjacent cylinders
indicates a cylinder head gasket leak. Check this
item before condemning the rings or valves.
TEST CONCLUSION :
13. To determine whether the rings or the valves are at
fault, squirt the equivalent of a tablespoon of heavy
oil into the combustion chamber. Crank the engine
to distribute the oil and repeat the compression test.
The oil will temporarily seal any leakage past the
rings. If approximately the same reading is obtained,
the rings are satisfactory, but the valves are leaking.
If compression has increased over the original
reading, there is leakage past the rings.
During a compression test, if the pressure fails to
climb steadily and remains the same during the
first two successive strokes, but climbs higher on
the succeeding strokes, or fails to climb during the
entire test, suspect a sticking valve.
12123 1 02/07/2004
B.10.A / 21
Valve drive Camshaft - Remove (B.10.A.40.44 - F.10.A.10)

CS540, CS640, CS520, CS660
NOTE: The camshaft bearings and tappets can only be serviced with engine removed from the vehicle.
1. Remove the engine front cover, and cylinder head.
Check the camshaft end play, see timing gears
section, and remove gear, install a new thrust plate
prior to reassembly if required.
After removal of the flywheel, and rear cover,
remove the camshaft oil pump drive gear (1).
TA60100057 1
2. Invert the engine on the stand, if camshaft bearings

are to be replaced, and remove the oil pan. Refer to
Oil pan - Remove (B.60.A.23 - F.10.A.10).
Carefully withdraw the camshaft from the front of
engine.
396-E-16_16 2
3. Lift out the tappets and place in a numbered rack

for reassembly.
396-E-23 3
12123 1 02/07/2004
B.10.A / 22
4. Inspect the camshaft bearings for wear or damage.

Measure the clearance between the internal
diameter of bearing and outside diameter of
respective journal, 0.074-0.178 mm (0.003-0.007
in).
TA6010071 4
5. If specification is exceeded install new bearings

using, Remover/Replacer Tool No 297117 and
handle, Tool No 291896. Refer to ENGINE -
Special tools (B.10.A - D.20.A.40).
6. To remove, position tool against bearing to be
removed and attach handle, driving bearing from
bore.
7. To install, align oil holes of new bearing with holes
in block, and drive bearing into bore using tools as
described.
NOTE: A positive alignment check can only be made with
crankshaft removed when a 4.6 mm (0.018 in) rod can be
passed down the oil passage from the crankshaft main
bearing. Bearing is correctly positioned when end of rod
passes through oil hole in the bearing.
12123 1 02/07/2004
B.10.A / 23
Valve drive Camshaft - Overhaul (B.10.A.40.44 - F.10.A.40)

CS540, CS640, CS520, CS660
1. Inspect the camshaft journals, lobes, for damage,

pitting, or heat discoloration. If any of these
conditions exist install a new camshaft.
396-E-23 1
2. Inspect the oil pump drive gear on camshaft for

broken or worn teeth, and mating gear on oil pump.
If any wear or damage is apparent fit new gears.
3. Check each tappet for wear or damage and
check diameters, if not to specification renew,
25.113-25.131 mm (0.99887-0.9894 in).
4. Measure the diameter and out-of-round condition of
bearing journals, if exceeded fit a new camshaft,
60.642-60.668 mm (2.3875-2.3885 in).
12123 1 02/07/2004
B.10.A / 24
Valve drive Camshaft - Install (B.10.A.40.44 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Apply petroleum jelly to each tappet foot, and coat

tappet body with oil. Install tappets in bores from
which they were removed.
396-E-23_17 1
2. Oil camshaft journals and apply petroleum jelly to

the cam lobes.
Install camshaft through front of engine.
396-E-16_18 2
3. Align the camshaft gear timing mark. Recheck end

play.
P396-E-36_9 3
12123 1 02/07/2004
B.10.A / 25
4. Install camshaft pump drive gear (1) at rear of

engine. Tighten the bolt (2) to torque of 57-77 Nm
(43-58 lb ft.).
10_30-50_66 4
12123 1 02/07/2004
B.10.A / 26
Valve drive - Overhaul (B.10.A.40 - F.10.A.40)

CS540, CS640, CS520, CS660
NOTE: Re-facing the valve seat should always be coordinated with re-facing of the valve to ensure a compression
tight fit.
1. Examine the valve seat inserts and re-face 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 chart
Cylinder head - General specification (B.10.A.72
- D.40.A.10). The new insert must be chilled in dry
ice prior to installation.
3. Valve seat specifications, Fig. 1.
Valve seat angle
Intake : 30.0 °-30.30 °
Exhaust : 45.0 °-45.30 °
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)
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 TA6010013 1
side in line with the valve seat concerned.
4. Check the width of the valve seat inserts, and as
required re-face by grinding to dimensions detailed
above.
5. 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), Fig. 2.
TA6010015 2
12123 1 02/07/2004
B.10.A / 27
6. 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.
Rotate a new or re-faced 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, Fig. 3, in the following manner.
Lower, the valve seats (1) Fig. 3, by removing
material from the top of seat using a, 30 ° grinding
wheel for exhaust valves and a 15 ° grinding wheel
for intake valves.
TA6010016 3
7. Raise, the valve seats (2) Fig. 3, by removing

material from the bottom of seat using a, 60 °
grinding wheel for exhaust valves and a 45 °
grinding wheel for intake valves.
8. Critical valve points:
Valve land edge (1)
Valve head (2)
Valve face angle (3)
Valve face (4)
Valve stem (5)
Valve tip (6)
TA6010017 4
9. Valve guides :
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, 0.140 mm (0.0055 in), on the exhaust
valve stem, Fig. 5.
NOTE: Production cylinder heads may have one or more
machined, oversize valve guide bores, or valves installed,
0.015 in (0.38 mm). Such cylinder heads have 15 or
VO15OS stamped on the cylinder head exhaust manifold
side adjacent to the valve concerned.
12123 1 02/07/2004
B.10.A / 28
10. Using reamer set, 295006, refer to ENGINE -

Special tools (B.10.A - D.20.A.40), 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
38 mm (0.015 in) oversize reamer, and 0.076 mm
(0.003 in) oversize pilot.
TA6010018 5
11. Valve springs :

Checked on a flat surface squareness, should not
exceed 1.52 mm (0.060 in), between the square,
and spring at the top edge, Fig. 6.
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 lb)
Loaded length = 1.4 in (35.69 mm) using a weight
of 61-69 kg (135-153 lb)
Ensure the valve spring retainer locks are in good
condition, and replace if worn or damaged.
TA6010019 6
12. Rocker shaft inspection and reassembly :

Separate rocker shaft assembly by removing the
cylinder head bolts (3) and withdraw the supports
(2) springs (1) rockers (4) and spacers (6).
13. Clean all components using approved cleaning
solution and make sure all oil passages are clear.
14. 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.
15. 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.
TA6010010 7
12123 1 02/07/2004
B.10.A / 29
16. 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.
17. Check the rocker shaft for signs of wear or damage
on internal and external diameters respectively.
18. Reassemble 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.
10_30-50_11 8
12123 1 02/07/2004
B.10.A / 30
Crankshaft Front seal - Remove (B.10.A.43.01 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove crankshaft pulley using Tool 297102 or

297262 (prior numbers 518 and 938), refer to
ENGINE - Special tools (B.10.A - D.20.A.40), or
suitable equivalent.
TA6010027_23 1
2. Remove the drive key (1).
BSC1133A 2
3. Withdraw wear sleeve (1), the seal (2), and the

O-ring (3).
NOTE: When removing oil seal, protect the flange of the
crankshaft with cloth and using a long screwdriver pry
out the seal.
10_63-68_06 3
12123 1 02/07/2004
B.10.A / 31
Crankshaft - Remove (B.10.A.43 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the engine, flywheel and oil pan, refer to

Flywheel - Remove (B.10.A.50 - F.10.A.10) and
Oil pan - Remove (B.60.A.23 - F.10.A.10).
Remove the connecting rod caps, main bearing
caps and liners, and identify to facilitate reassembly.
396-E-13 1
2. Carefully remove crankshaft from cylinder block.
6010065 2
12123 1 02/07/2004
B.10.A / 32
Crankshaft - Install (B.10.A.43 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Check the crankshaft bearing clearance using a

"plastigauge" as follows.
Position a piece of correct size "plastigauge" across
the full width of the bearing cap, approximately 6.35
mm (0.25 in) off centre.
TA6010068 1
2. Install the cap and tighten bolts to 149 Nm (110 lb

ft).
Remove the cap and use the scale to check the
width of the flattened "plastigauge", Fig.1.
Widest point, of gauge establishes the minimum
clearance.
Narrowest point, of gauge establishes maximum
clearance. The difference between the two readings
is the taper.
NOTE: Normally main bearing journals wear evenly
and will not be out-of-round, but if a bearing which is to
specification is fitted to an out-of-round journal, ensure
liner suits maximum diameter of journal.
6010069 2
3. If the combinations of bearings do not produce

specified clearance, refinish crankshaft and fit
appropriate size service bearings.
IMPORTANT: Engines may be assembled with bearings
of different material, but bearings of the same material
must be used on the same journal.
4. Ensure bearing liners are clean and align with the
oil galleries and integral oil jets. The tang on the
bearing must align with the slots in the block and
cap.
396-E-26_20 3
12123 1 02/07/2004
B.10.A / 33
5. Coat liners with oil and install crankshaft.
6010065 4
6. Install a thrust bearing cap with flange type bearing

first, installing remaining bearing caps to their
original location and tightening finger tight.
396-E-9 5
7. Tighten the main bearing caps in two stages:

Stage 1, tighten all bolts to a torque of 81 Nm (60
lb ft).
Stage 2, using a torque angle gauge tighten all bolts
a further 90 ° in a single stroke.
6010069_21 6
8. Check crankshaft end play with a dial indicator

gauge, pry crankshaft towards front of engine and
set dial indicator to zero. Pry crankshaft towards
rear of engine and note reading on dial if end play
exceeds 0.10-0.20 mm (0.004-0.008 in), fig. 8, fit a
new thrust bearing.
BSB0079A 7
12123 1 02/07/2004
B.10.A / 34
9. If the end play is less than specification check thrust

bearing for burrs, scratches, or dirt, and re align
thrust bearing as in step 8.
Install rear crankshaft oil seal as previously
described in rear cover plate removal.
NOTE: Do not pre-install seal into retainer. To ensure seal
concentricity, it must be assembled with rear plate and
installation tool when fitted to crankshaft.
TA6010070 8
10. Install the camshaft idler gear ensuring the timing

marks are correctly aligned.
P396-E-36_22 9
12123 1 02/07/2004
B.10.A / 35
Crankshaft Front seal - Install (B.10.A.43.01 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Clean all parts and install a new O-ring (1).
10_63-68_07 1
2. Lubricate the seal (1) and push onto the seal

installation tool (3) (no.297115), refer to ENGINE -
NOTE: The installation tool (3) must be used to install
the seal. Failure to use the tool will result in incorrect
positioning of the seal and consequential leakage after a
few hours of operation.
SMC10013 2
3. Locate tool onto crankshaft.

Slowly screw bolt into end of crankshaft to install
seal.
BSC1130A 3
12123 1 02/07/2004
B.10.A / 36
4. Continue turning the bolt until face of the tool (3)

almost touches face of front timing cover.
IMPORTANT: Use the minimum of effort when turning the
bolt and DO NOT force tool against face of front cover.
BSC1131A 4
5. Coat a new wear sleeve (1) with oil.

Gently push the wear sleeve (1) over the crankshaft
nose and into the centre of the seal.
10_63-68_11 5
6. Install drive key (1).
BSC1133A 6
7. Install front crankshaft pulley using T bar tool No

297262 (prior number 938), refer to ENGINE -
Special tools (B.10.A - D.20.A.40), or suitable
equivalent.
Check and top up engine with oil as specified in the
CS Operator’s manual.
10_63-68_12 7
12123 1 02/07/2004
B.10.A / 37
Crankshaft - Overhaul (B.10.A.43 - F.10.A.40)

CS540, CS640, CS520, CS660
NOTE: Current production engines may have a crankshaft with main or crank pin journals ground 0.25 mm (0.010
in) under size. These are identified with the letters 010 MUS and/or 010 PUS respectively, letters being stamped on
one of the crankshaft counter balance weights.
1. Thoroughly clean bearings, journals, and caps,
and inspect for wear, scores, or damage replace
as required.
NOTE: It is recommended that all the main bearings
should be replaced if it is found necessary to replace any
one set of main bearings.
10_51-62_27 1
2. If crankshaft timing gear teeth are worn or damaged

it will be necessary to replace the complete
crankshaft assembly.
10_51-62_28 2
3. Wash the crankshaft and drilled passages in a

suitable solvent. Dress minor imperfections using
an oil stone but for severely marked journals
machine to the next under size bearing size.
TA6010067 3
12123 1 02/07/2004
B.10.A / 38
4. Measure diameter of each journal, Fig.3, in four

places to determine out-of-round, taper, or wear.
Measuring, A, compared with B, indicates vertical
taper. Measuring, C, compared with D, indicates
horizontal taper. Measuring, A and B, compared
with C and D, indicates journal out-of-round.
5. If the journal exceeds specified limits refer to
ENGINE - General specification (B.10.A -
D.40.A.10) and refinish journal to the next under
size bearing.
6. Examine the rear oil seal journal for score marks,
remove minor imperfections with fine emery cloth,
and if severely damaged renew the crankshaft.
12123 1 02/07/2004
B.10.A / 39
Timing gear - Remove (B.10.A.45 - F.10.A.10)

CS540, CS640, CS520, CS660
IMPORTANT: If the injection pump timing has been checked ensure the timing pins 295005 and 297672 have been
before removed before proceeding. Refer to Fuel injection pump - Timing check (B.20.A.21 - F.40.B.12).
1. Using puller, 297102 (518 or FT.9539), and shaft
protector 297107 (625-A or 9212), refer to ENGINE
- Special tools (B.10.A - D.20.A.40), remove
crankshaft damper.
TA6010027 1
2. Remove the front cover plate.
BSD1848A 2
3. When the engine timing has been checked (as

described in Fuel injection pump - Timing check
(B.20.A.21 - F.40.B.12)) the timing marks (dots) on
the crankshaft and camshaft timing gears align.
Camshaft gear (1)
Crankshaft timing gear (2)
Camshaft idler gear (3)
Injection pump drive gear (4)
NOTE: The crankshaft timing gear (2) should not be
removed. The gear is heat shrunk on to the crankshaft
and aligned to the crankshaft No1 pin, to within 0.10 mm
(0.004 in). If the gear is damaged a new crankshaft is
required.
P396-E-36_5 3
12123 1 02/07/2004
B.10.A / 40
4. Before removing the timing gears perform the

following checks:
Use a dial indicator or feeler gauge, Fig. 4, to
measure the backlash between each set of gears.
Rotate the gears and check the backlash at four
equal points on the gears. Renew if the backlash
exceeds the following:
Crankshaft to camshaft idler gear, 0.1-0.36 mm
(0.004-0.014 in)
Camshaft to camshaft idler gear, 0.1-0.36 mm
(0.004-0.014 in)
Fuel injection pump to camshaft idler gear 0.10-0.48
mm (0.004-0.019 in)
TA60100029 4
5. Check camshaft gear end float as follows:

Pry the camshaft gear using a lever, away from
thrust plate. Using a dial indicator or feeler gauge,
check the clearance.
P396-E-28 5
6. If clearance is outside 0.05-1.8 mm (0.002-0.007 in)

limit, fit a new camshaft thrust plate, item (1) Fig. 7.
NOTE: The camshaft gear is an interference fit with the
camshaft and removal requires a three legged puller. It
is recommended that this gear is only removed when
necessary and during a total engine rebuild. This will
enable both the gear and camshaft to be removed from
the front of the engine.
396-E-45 6
7. Check idler gear end float using similar procedure

described for the camshaft gear. If outside limits of
0.073-0.35 mm (0.003 in-0.014 in) fit a new idler
gear wear plate (1).
P396-E-46 7
12123 1 02/07/2004
B.10.A / 41
8. To remove the injection pump drive gear (1), remove

the 4 retaining bolts.
P396-E-36_6 8
9. If required the timing gear rear cover plate may

now be removed. Remove the six retaining bolts
and carefully pry the cover from the engine block.
When replacing the cover tighten retaining bolts to a
torque of 24 Nm (18 lb ft).
10_30-50_31 9
12123 1 02/07/2004
B.10.A / 42
Timing gear - Install (B.10.A.45 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Wash the gears using a suitable solvent, and

examine gear teeth for wear, burrs, or scratches.
Minor marks can be removed using a fine abrasive,
thoroughly clean before reassembly.
Ensure the camshaft idler gear adaptor is free from
obstruction and bushing is not damaged. Camshaft
key and key way should be checked for damage
and repaired as required.
10_30-50_32 1
2. Position piston no.1 at Top Dead Centre and install

timing pin 297672, refer to ENGINE - Special tools
(B.10.A - D.20.A.40).
BSC1304A_7 2
3. Ensure the timing marks on the pump are aligned

and screw the rigid timing pin 295005, refer ENGINE
- Special tools (B.10.A - D.20.A.40), through the
pump flange and timing plate.
BSC1303A 3
12123 1 02/07/2004
B.10.A / 43
4. If the pump has been removed during engine

overhaul refit pump onto engine.
BSD1847A_8 4
5. Install timing gears ensuring the timing marks on the

crankshaft, idler and camshaft gears align.
Fit the pump drive gear and remove pump timing
pin.
Torque bolts as follows.
Camshaft gear 69 Nm (51 lb ft)
Idler gear 204-279 Nm (150-205 lb ft)
Pump drive gear 38 Nm (28 lb ft).
P396-E-36_9 5
6. Remove crankshaft timing pin and install plug.
BSD1542B_10 6
7. Position gasket on the front cover plate.

Install the front cover, ensuring alignment with dowel
pins. Tighten the retaining bolts in the 1-4 sequence
shown to a torque of 34-41 Nm (25-30 lb ft).
Install the oil pan as described on the following
page.
Install new front crankshaft oil seal as described in
Crankshaft Front seal - Install (B.10.A.43.01 -
F.10.A.15).
10_30-50_38 7
12123 1 02/07/2004
B.10.A / 44
Connecting rod and piston - Remove (B.10.A.47 - F.10.A.10)

CS540, CS640, CS520, CS660
NOTE: The pistons, crankshaft and cylinder block can only be serviced with the engine removed from the vehicle.
1. Remove the oil pan. Refer to Oil pan - Remove
(B.60.A.23 - F.10.A.10).
With cylinder head removed clean off any ridge from
the top of the cylinder bores, with a ridge remover to
enable removal of the pistons, this is essential if old
pistons are to be reused as failure to do so could
result in ring land damage.
BSD1853A 1
2. With the piston at the bottom of the stroke remove

the end cap bolts, cap, and liner.
TA60100033 2
3. Using the handle end of a hammer push the piston

assembly out through the top of the block, and
remove the bearing liner from the connecting rod,
Fig.2.
NOTE: Bearing caps and liners must be kept with their
respective connecting rods.
BSD1850A 3
4. Turn the crankshaft again and repeat the process

for the remaining pistons.
12123 1 02/07/2004
B.10.A / 45
Connecting rod and piston - Overhaul (B.10.A.47 - F.10.A.40)

CS540, CS640, CS520, CS660
1. Remove piston pin snap rings from each side of

piston and remove pin. Using an expander, Tool
No.296028, refer to ENGINE - Special tools
(B.10.A - D.20.A.40) and remove the piston rings.
Ensure each piston and rod assembly, remains
matched together for reassembly into the cylinder
block.
TA6010034 1
2. Clean the piston, and connecting rod assembly, in

a suitable solvent and inspect for damage to ring
lands, skirts, or pin bosses.
3. Check connecting rod components for damage, and
place in an alignment fixture to check for distortion,
and ensure that any distortion, is within specification
as follows.
Maximum twist 0.30 mm (0.012 in).
Maximum Bend 0.10 mm (0.004 in).
4. Check piston pin bushing for damage or wear in the
following manner.
Measure the outside diameter of the piston pin, and
inside diameter of the connecting rod bushing, to
the following:
44.442-44.447 mm (1.7497-17499 in).
44.460-44.467 mm (1.750-1.751 in)
5. If connecting rod bushes are not to specification
replace the old bush, using the following procedure.
6. Place the connecting rod securely in a bench press.
Manufacture from suitable bar stock, a press tool
with the end face ground at an angle, to suit the
connecting rod bush side face. Position the tool on
the bush, and gently drive the bush from its position.
It is recommended a guide is manufactured to assist
alignment of the bar stock during this operation.
7. A new bush can then be fitted in a similar manner,
by using a suitable piece of bar stock, with an end
face machined flat to suit the standard parallel bush.
Use a guide as described, and gently drive in the
new bush into the connecting rod.
NOTE: Ensure the split in the small end bush is at right
angles to centre line of connecting rod.
6010035 2
12123 1 02/07/2004
B.10.A / 46
8. After installation grind the side faces of the new

bush to match the side faces of the connecting rod.
Ensure all sharp edges are removed, and loose
chippings are cleaned from the connecting rod
before reassembly into the engine.
With a new bush fitted drill a hole through the top of
the connecting rod using a 4.6 mm (0.187 in) bit.
Drill through the existing oil hole, Fig. 3.
TA6010036 3
9. Use an expanding reamer to obtain correct bushing

to piston pin clearance referring to specification
section. Remove burrs, and chippings, before
refitting.
On reassembly of piston lubricate all of the
components with engine oil. Assemble the
connecting rod, and piston, with the letter or grade
mark on the piston, aligned to the pip (1), on the
connecting rod. Install the piston pin and retainers.
TA6010045 4
12123 1 02/07/2004
B.10.A / 47
Connecting rod and piston - Install (B.10.A.47 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Select the correct bearing liners as in the following

crankshaft section, and install in the rod and cap,
ensure the liner tang locates in the slots of the rod
and cap.
Turn the crankshaft to position No 1 crank pin at
the bottom of the stroke, and lubricate all parts with
new engine oil.
Locate piston into bore ensuring the dot on the
connecting rod and arrow or grade letter on the
pistons face towards the front of the engine.
BDS1850A 1
2. Using ring compressor, Tool No.296042, refer to

ENGINE - Special tools (B.10.A - D.20.A.40)and a
soft drive, slide pistons into bores.
6010050 2
3. Ensure the connecting rod bearing liner, seats on

the crank pin with the bearing cap fitted, to the
connecting rod as a matched assembly. Fit new
bolts lubricated with oil, and tighten to a torque
value of 149 Nm (110 lb ft).
Using feeler gauges, check the side clearance of
each connecting rod to crankshaft, Fig. 3, 0.13-0.33
mm (0.005-0.013 in) and continue for remaining
assemblies.
Refit the oil pump tube / screen and oil pan (Oil pan
- Install (B.60.A.23 - F.10.A.15)), refill engine oil
and coolant, and run the engine checking for leaks.
TA6010051 3
12123 1 02/07/2004
B.10.A / 48
Flywheel - Remove (B.10.A.50 - F.10.A.10)

CS540, CS640, CS520, CS660
1. To gain access to the flywheel remove the engine.

Prior to removing flywheel use a dial indicator to
measure flywheel run out. The maximum total
indicator reading should be 0.127 mm (0.005 in)
If not to specification check crankshaft to flywheel
seating.
TA6010053 1
2. Support flywheel, remove retaining bolts and

separate flywheel from crankshaft.
BSD1851A 2
12123 1 02/07/2004
B.10.A / 49
Flywheel - Install (B.10.A.50 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Inspect the flywheel ring gear, and if damaged

renew in the following manner,
Cut old ring gear free from the flywheel.
Clean the mating surfaces of the new ring gear,
and flywheel.
10_30-50_44_37 1
2. Use temperature indicating crayons to mark the side

face of the ring gear in six equal places, mark with
a 204 °C (400 °F) crayon at a point 13 mm (0.5 in)
below the root of the teeth, and mark with a 212 °C (
450 °F) crayon at a point just below root of the teeth.
Use an oxy-acetylene torch with a tip size of No.2
maximum, and direct the flame against the internal
face of the gear.
3. Quickly place the hot gear on the flywheel, with flat
face against the shoulder on the flywheel. The gear
to flywheel run out should be checked using a dial
indicator and should not exceed a Total Indicator
Reading of 0.63 mm (0.025 in).
4. Clean the crankshaft rear flange and mating surface
of the flywheel. Install the flywheel, torquing the
bolts to, 197 Nm (145 lb ft).
BSD1851A 2
12123 1 02/07/2004
B.10.A / 50
Cylinder block - Overhaul (B.10.A.70 - F.10.A.40)

CS540, CS640, CS520, CS660
TA6010038 1
Cylinder block core plug and sensor ports, front and left-hand side
TA6010039 2
Cylinder block core plug and sensor ports, rear and right-hand side
1. Cylinder block plugs, and senders, require changing

if leaking or rusty, and must be replaced. Clean
the old sealant off the block, and fit new plugs with
sealer.
Fig. 1, refers to the front and left hand side of the
cylinder block.
Plug (1) torque to 8-14 Nm (6-10 lb ft)
Use sealant, E.
Plug (2) torque 27-47 Nm (20-35 lb ft)
Use sealant, E.
Pipe plug (3) torque to 24-34 Nm (18-25 lb ft)
Use sealant, E.
Plug (4) drive in to block.
Use sealant G.
NOTE: New part mating faces, and threads, should
be coated in sealant, refer to ENGINE - General
specification (B.10.A - D.40.A.10). Assemble in the
following manner.
12123 1 02/07/2004
B.10.A / 51
2. Fig. 2, refers to the rear and right hand side of the

block.
Pipe plug (1) torque to 8-14 Nm (6-10 lb ft).
Use sealant, E.
Pipe plug (2) torque to 24-34 Nm (18-25 lb ft).
Use sealant, E.
Plug (3) drive into block.
Use sealant, G.
Plug (4) torque to 54-81 Nm (40-60 lb ft),
Use sealant, E.
Oil jets (5) replace with new if damaged, apply
engine oil only on reassembly "Do not use sealant"
3. Cylinder bore :
Check the cylinder bore for scuffing or rings
around the ring travel area. Irregularities can be
felt by running a finger over the surface. To check
out-of-roundness, wear, or taper, use a telescopic
gauge, Fig. 3.
Measure lengthwise,
A, to B, and C, to D, and compare dimensions.
Variances between the readings will indicate "taper".
Measure crosswise,
C, to D, and compare dimensions lengthwise. A, to
B. Variances will indicate an out-of-round condition.
Taper of cylinder bore,
repair limit- 0.025 mm (0.001 in)
3
wear limit - 0.127 mm (0.005 in) TA6010040
Cylinder bore out of round,

repair limit - 0.03 mm (0.0015 in)
wear limit- 0.127 mm (0.005 in)
Cylinder bore diameter,
111.778-111.803 mm (4.4007-4.4017 in).
NOTE: Repair limit’ refers to the tolerance allowed after a
repair has been performed, i.e. the repair must be within
the repair limit. The ‘Wear Limit’ is the tolerance prior to
repair.
4. Where only minor imperfections exist and bores are
to specification, hone the bores prior to installing
new piston rings. Provided piston to bore clearance,
does not exceed 0.250 mm (0.011 in).
5. Sleeving of the cylinder bores becomes expedient
when:
Minor imperfections to the bores are outside of the
specification.
Oil consumption is high.
Replacing sleeves, installed in service.
Cylinder bore is damaged beyond re-boring limits.
Oversize pistons available:
0.020 in (0.51 mm)
0.040 in (1.00 mm)
NOTE: Oversize pistons are available in specific markets
only. In markets where these are available the bore
should be bored or honed to fit the next oversize piston.
TA6010041 4
12123 1 02/07/2004
B.10.A / 52
Cylinder block - Rebore (B.10.A.70 - F.75.C.30)

CS540, CS640, CS520, CS660
1. Measure the outside diameter (1) of the sleeve

in several places, and average the dimension.
Counter bore the cylinder block (see step 2) using
the average dimension to obtain a press fit, between
bore and sleeve. Interference of sleeve to the
cylinder bore to be 0.025-0.076 mm (0.001-0.003
in).
TA6010042 1
2. Counter bore to a depth of 204.7 mm (8.06 in), from

the block face, surface finish of the bore is not to
exceed (80 microns). Leave a step at the bottom of
the bore a minimum of 9.60-10.16 mm (0.38-0.400
in), allowing for run out of chamfers.
3. Bore through diameter, to the diameter of,
114.3-116.0 mm (4.454-4.456 in).
4. Clean the cylinder bores and thoroughly dry.
5. Grease the sleeve with a general purpose grease
and press the sleeve home to the lip in the bore.
The top of the sleeve should protrude through the
top of the block, 0.127-1.0 mm (0.005-0.040 in).
6. Bore the sleeve to, 110.00-111.76 mm
(4.3985-4.400 in).
7. Skim the block face, and top of sleeves, to achieve
the specified flatness of 0.08 mm (0.003 in) in any
152 mm (6 in) 0.03 mm (0.001 in) in any 25.4
mm (1 in). A chamfer in the internal diameter at
the top of the sleeve to 45 ° x 0.5 mm (0.020 in)
should be maintained, to prevent piston damage
on re-assembly.
8. Break the sharp edge at the bottom of the sleeve
prior to honing.
9. Hone the cylinder bore to, Grade B, 111.790-111.803
mm (4.4012-4.4017 in.)
Maximum taper,
0.025 mm (0.001 in) through to bottom of the bore.
Maximum Quality,
0.038 mm (0.0015 in)
NOTE: Surface finish to be an average of 20 to 30
Microns, cross hatched at 35 °-55 °.
12123 1 02/07/2004
B.10.A / 53
Cylinder block - Assemble (B.10.A.70 - F.10.A.20)

CS540, CS640, CS520, CS660
NOTE: Pistons that are replaced must be of the same type that were removed and have the same identification
letters, and numbers, as embossed on the piston crown
1. Upon reassembly with the piston at Top Dead
Centre, ensure the piston to block height is correct
using a dial indicator to, Fig. 1.
0.13-0.38 mm (0.005-0.015 in)
TA6010043 1
2. Check the piston to bore clearance in the following

manner.
A, Measure the cylinder bore diameter at point (A),
82.6 mm (3.25 in.) from the top of the block.
B, Measure the diameter of the piston at point (B),
25.4 mm (1.00 in) from the bottom of the piston.
C, Subtract piston diameter from the bore diameter
and the resultant figure for a new, unused engine
should be:
152-0.178 mm (0.0060-0.0070 in) After an engine
has run and settled down the maximum bore to
piston clearance allowed is 0.250 mm. (0.011 in).
Where pistons are only available as standard. New
pistons should always be fitted if the clearance
2
exceeds specification. TA6010044
D, If clearance is "greater" try a similar new piston, if

limit is still exceeded it will be necessary to re-bore
and re-sleeve.
E, If the clearance is "less" hone bore to obtain
desired clearance.
3. Lubricate all of the components with engine oil and
assemble the connecting rod, and piston, with the
letter or grade mark on the piston, aligned to the
pip (1) on the connecting rod. Install the piston pin
and retainers.
TA6010045_19 3
12123 1 02/07/2004
B.10.A / 54
4. Check the piston ring gap width, using a feeler

gauge, in a vertical position at the top, middle, and
bottom of the bore, Fig. 4.
Ring gap specifications (new rings and bore):
Top compression ring
0.29-0.53 mm (0.012-0.021 in),
2nd compression ring
0.49-0.63 mm (0.020-0.029 in),
Oil control ring.
0.29-0.58 mm (0.012-0.023 in),
TA6010046 4
5. Using a new piston ring, check with a feeler gauge,

the gap between the ring and groove.
2nd compression ring - .
0.06-0.105 mm (0.0023-0.0041 in),
Oil control ring
0.030-0.070 mm (0.0011-0.0028 in).
TA6010048 5
6. Install the piston rings, but note the following:

Always ensure the correct expander, Tool
No.296028, refer to ENGINE - Special tools
(B.10.A - D.20.A.40), is used to remove or install
rings, Fig.5.
TA6010047 6
7. Install top and second compression rings with the

word top towards the top of the piston. Ensure the
ring gaps are staggered a minimum of 120 ° from
each other on the diameter, and with no gap on the
thrust side of the piston.
NOTE: Before installing new pistons and rings into a used
cylinder bore, remove the high polish from the cylinder
walls by honing as previously described.
BDS1856A 7
12123 1 02/07/2004
B.10.A / 55
Cylinder head - Remove (B.10.A.72 - F.10.A.10)

CS540, CS640, CS520, CS660
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).
ZDA7524A 1
2. Drain the coolant from the engine block, using the

drain tap (3) on left hand side of the radiator.
ZDA6106A 2
3. Remove all necessary hardware and components in

order to gain access to the cylinder head.
4. Remove the alternator, water pump and air
conditioning compressor drive belt.
ZDA6251A_3 3
12123 1 02/07/2004
B.10.A / 56
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.
10_24-29_04 4
6. Remove injectors from the cylinder head.
10_24-29_05 5
7. Remove the turbocharger assembly, ensuring all

openings are capped to prevent dirt ingress.
10_24-29_06 6
8. Remove the thermostat housing (1) and water pump

housing (2).
10_24-29_07 7
12123 1 02/07/2004
B.10.A / 57
9. Remove the rocker cover and gasket.
10_24-29_08 8
10. Loosen the rocker shaft retaining bolts (which also

serve as head bolts) evenly and alternately and
remove the rocker shaft assembly.
NOTE: Leave bolts in the rocker shaft supports during
removal, as they retain the support on the shaft.
10_24-29_09 9
11. Remove push rods in turn and place in a numbered

rack to maintain the same position for reassembly.
10_24-29_10 10
12. Remove remaining cylinder head bolts by working

progressively from each end of the cylinder head
towards the centre.
Carefully lift the cylinder head assembly away from
the engine block.
BSD1849A 11
12123 1 02/07/2004
B.10.A / 58
Cylinder head - Disassemble (B.10.A.72 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Using a valve spring compressor, tool No.291050

(1), refer to ENGINE - Special tools (B.10.A -
D.20.A.40), remove the retainer locks (2) and place
in a numbered rack.
TA601001 1 1
2. Clean the cylinder head, and remove carbon

deposits from around the valve heads.
10_24-29_13 2
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
12123 1 02/07/2004
B.10.A / 59
Cylinder head - Overhaul (B.10.A.72 - F.10.A.40)

CS540, CS640, CS520, CS660
1. Replace cylinder head core plugs if discolored

(rusty), or leaking. Before fitting new plugs remove
all old sealer from the cylinder head. Apply sealant
G, see ENGINE - General specification (B.10.A -
D.40.A.10), 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 rear of the cylinder
head.
5 off, in the intake face.
TA601008 1
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.
3. Inspect cylinder head for nicks and burrs on mating
face, Remove using a suitable abrasive and ensure
faces are clean after repair.
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.
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
4. 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.
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 reinstalled
in the bolt holes they were checked in.
10_30-50_03 3
12123 1 02/07/2004
B.10.A / 60
Cylinder head - Assemble (B.10.A.72 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Insert the valves into the guide bores from which

they were removed and lap with a suitable paste.
Ensure all traces of paste is removed after lapping.
Use a spring compressor to reassemble the valves,
valve springs, retainers, rotators, and collets, and
install new valve stem seals.
NOTE: Lubricate all components with clean engine oil
on reassembly.
TA6010011 1
2. Install new gasket and lower cylinder head into

place while ensuring the gasket remains in position.
Loosely position all cylinder head bolts except those
which retain the rocker shaft assembly.
NOTE: Cylinder head bolts may only be removed and
refitted four times after which they must be replaced with
new parts.
BSD1849A_4 2
3. Install rocker push rods in cylinder head and locate

rocker shaft assembly onto cylinder head using the
longer cylinder head bolts.
10_30-50_03 3
12123 1 02/07/2004
B.10.A / 61
4. Tighten the cylinder head bolts in sequence

progressively in the following stages, Fig. 4.
NOTE: Lightly lubricate the bolts prior to assembly, and
tighten to the torque specification, with the engine cold.
10_30-50_14 4
5. Stage 1, all bolts, 55 Nm (40 lb ft)
BSB0080A 5
6. Stage 2, all bolts, 95 Nm (70 lb ft)
BSB0081A 6
7. Stage 3, all bolts, a further 90 ° using a torque angle

gauge, Fig. 7.
BSB0082A 7
12123 1 02/07/2004
B.10.A / 62
8. Stage 4, Rocker shaft securing bolts only, tighten a

further 45 °, Fig.9, using a torque angle gauge. In
sequence, 2, 8, 10, 16, 18, 24, 26.
BSB0083A 8
9. Stage 4 Rocker shaft bolts
BSB0084A 9
10. Adjust valve clearance setting with each piston in

turn at Top Dead Centre, and rockers free to move,
Fig. 10.
NOTE: Valve clearance is to be set, only when the engine
is cold.
10_30-50_20 10
11. Install the injectors with new seat washers, cork

seals, and torque to 23 Nm (17 lb ft) Fig. 11
Intake valve clearance,
0.36-0.46 mm (0.014-0.018 in).
Exhaust valve clearance,
0.43-0.53 mm (0.017-0.021 in)..
Install the injector lines and torque to 24 Nm (18 lb
ft). Install the leak off line with new washers, and
torque the leak off banjo bolts to, 6 Nm (4.4 lb ft).
NOTE: Hold the leak off plastic tubing when tightening to
prevent the pipes pivoting, during torque up.
10_30-50_21 11
12123 1 02/07/2004
B.10.A / 63
12. Exhaust manifold bolts are to be refitted and

tightened to a torque of, 38 Nm (28 lb ft).
Intake manifold bolts are to be refitted and tightened
to a torque of, 38 Nm (28 lb ft).
10_30-50_22 12
13. Using new gaskets install intake and exhaust

manifolds. Initially install all bolts finger tight
ensuring the gaskets are aligned with the inlet and
exhaust ports.
14. Tighten the bolts to a torque of 61 Nm (45 lb ft)
working from the central bolts outwards.
15. Re tighten the bolts to a torque of 61 Nm (45 lb ft).
NOTE: When the manifold bolts are torqued the gaskets
may show signs of distortion between the inlet and
exhaust ports. This is normal for this type of gasket and is
the reason for the re-torque procedure.
12123 1 02/07/2004
B.10.A / 64
Rear cover - Remove (B.10.A.76 - F.10.A.10)

CS540, CS640, CS520, CS660
1. To gain access to the engine oil pump, camshaft

gear, or end of crankshaft remove the oil pan and
flywheel, refer to Oil pan - Remove (B.60.A.23 -
F.10.A.10) and Flywheel - Remove (B.10.A.50 -
F.10.A.10).
2. Remove the 12 attaching bolts, and gently pry off
cover plate (1).
P396-E-54 1
3. Clean off all sealer, remove crankshaft oil seal, and

check for damage or distortion around the sealing
faces.
12123 1 02/07/2004
B.10.A / 65
Rear cover - Install (B.10.A.76 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install new gasket and rear plate, tightening the

retaining bolts (2) and (3), finger tight, Fig.1.
P396-E-54 1
2. Apply a liberal coating of new engine oil on a new

oil seal. and position the rear seal over the end of
the crankshaft. Locate tool, No 297252, (1), Fig.2,
(ENGINE - Special tools (B.10.A - D.20.A.40)) on
the end of the crankshaft using the three attaching
bolts. Tighten evenly, and squarely, until the seal
is fully seated.
As an alternative the rear crankshaft oil seal can be
installed using the following installation tool.
TA6010054 2
3. Apply a liberal coating of clean engine oil to the

rear seal retainer, seal, and journal. A new seal
should be mounted on the crankshaft, then bolt tool
297194, (1), Fig. 3, to the crankshaft end and install
the new seal squarely.
Secure centre stock of tool to crankshaft flange with
two screws. Assemble cylinder end plate to centre
stock and secure with nut and washer as in, Fig. 3.
Tighten the nut until outer diameter of tool abuts
retainer. Tool must not be over tightened as stress
and distortion could be imposed on the retainer.
TA6010055 3
12123 1 02/07/2004
B.10.A / 66
4. Remove the tool after assembly.

NOTE: The first seal replacement should be pushed into
retainer with plain end of tool and subsequent seals with
stepped end of tool which will reposition seal 1.52 mm
(0.060 in) further in.
TA6010056 4
5. Place a straight edge along the rear of the engine

block above the seal carrier. Ensure the edge of
the carrier is aligned to the block to within 0.15
mm, protruding or 0.22 mm recessed. If not within
this specification orientate the carrier around the
slotted bolts (2) and (3) Fig. 1. Hand tighten this
bolt followed by the remaining bolts and ensure the
carrier is still correctly aligned. Fully tighten the
twelve bolts, in sequence to 11-14 Nm (8-10 lb ft)
and then 16-23 Nm (12-17 lb ft), Fig. 1.
10_30-50_40_33 5
6. Place a dial indicator, on the end of the crankshaft

and ensure seal runout is within 0.51 mm (0.020 in)
Total indicator reading.
Refit the oil pan. Refer to Oil pan - Install
(B.60.A.23 - F.10.A.15).
TA6010056_11 6
12123 1 02/07/2004
B.10.A / 67

CS540, CS640, CS520, CS660
IMPORTANT: When effecting a repair the cause of the problem must be investigated and corrected to avoid
repeat failures.

Engine does not develop Clogged air cleaner Clean or renew element
full power
Fuel line obstructed Clean
Faulty injectors Clean and reset
Incorrect valve clearance adjustment Check and reset
Burnt, worn or sticking valves Replace valves with new or oversize,
and/or machine the valve guide bores
Blown head gasket Check head flatness and fit new gasket
Incorrect fuel delivery Check injectors and pump
Low cylinder compression Renew piston rings or re-bore/re-sleeve
as necessary
Oil pressure warning light Bulb burnt out Renew bulb
fails to operate
Warning Light pressure switch faulty Renew pressure switch
Warning light circuit faulty Check and renew wiring
Excessive exhaust smoke Oil leak on compressor or turbine side of Overhaul turbocharger
turbocharger, where fitted
Exhaust leak on exhaust manifold side of Fit new gasket
turbocharger, where fitted
Air cleaner dirty or restricted Clean
Excessive fuel delivery Overhaul injection pump and injectors
Engine knocks Diluted or thin oil Check crankshaft bearings for damage,
change as required. Drain and refill with
specified oil and renew filter. Ascertain
cause of dilution
Insufficient oil supply Check oil level and top up as necessary.
Overhaul or renew pump as necessary.
Check oil filter is not clogged
Low oil pressure Overhaul pump or relief valve as necessary
Excessive crankshaft end play Install new thrust bearing liner
Flywheel or ring gear runout excessive Skim flywheel or fit new ring gear
Excessive connecting rod or main bearing Install new bearing inserts and/or regrind
clearance crankshaft
Bent or twisted connecting rods Renew connecting rods
Crankshaft journals out-of-round Regrind crankshaft and fit under size
bearing inserts
Excessive piston-to-cylinder bore Re-bore/re-sleeve block and fit new
clearance pistons
Excessive piston ring clearance Fit new pistons and rings
Broken rings Fit new rings, check bore and pistons for
damage
Excessive piston pin clearance Fit new piston or pin
Piston pin retainer loose or missing Install new retainer, and check bore/pistons
for damage
Excessive camshaft play Install new thrust plate
Imperfections on timing gear teeth Renew timing gear
Excessive timing gear backlash Check and adjust backlash / renew timing
gear
12123 1 02/07/2004
B.10.A / 68

Engine overheats Hose connection leaking or collapsed Tighten hose connection, renew hose if
damaged
Radiator cap defective or not sealing Renew radiator cap
Radiator leakage Repair/renew radiator
Improper fan belt adjustment Re-adjust fan belt
Radiator fins restricted Clean with compressed air
Faulty thermostat Renew thermostat
Internal engine leakage Check for source of leakage, renew gasket
or defective parts
Water pump faulty Overhaul water pump
Exhaust gas leakage into cooling system Renew cylinder head gasket, check head
for damage or distortion
Coolant aeration Tighten all connections and check coolant
level is correct. Ensure cylinder head
gasket has not blown
Cylinder head gasket improperly installed Renew cylinder head gasket
Hot spot due to rust and scale or clogged Reverse flush entire cooling system
water jackets
Obstruction to radiator air flow Remove the obstruction
Extended engine idling Do not allow engine to idle for long periods
Oil cooler tube blocked Clean
Radiator core tubes blocked Check free flow
Water temperature gauge Faulty temperature sender Renew sender switch
fails to reach normal
operating temperature
Incorrect or faulty thermostat Renew thermostat
Faulty water temperature gauge Renew temperature gauge
Low oil pressure Engine oil level low Top up, as necessary
Wrong grade of oil Drain and refill with correct grade of oil
Blocked oil pump sump screen Clean pump screen
Oil pressure relief valve faulty Fit new relief valve
Oil pump worn Renew oil pump
Excessive oil pump rotor and shaft Overhaul pump
assembly clearance
Excessive main or connecting rod bearing Install new bearings inserts and / or regrind
clearance crankshaft if necessary
Excessive oil Engine oil level too high Reduce oil level
consumption
External oil leaks Renew gaskets and seals, where
necessary. Check mating surfaces for
damage or distortion
Worn valves, valve guides or bores Renew
Cylinder head gasket leaking Renew gasket. Check head for damage
or distortion
Oil loss past the pistons and rings Renew rings and/or re-bore/ re-sleeve
block as necessary
Oil cooler leak Repair/renew oil cooler assembly
Engine tends to keep Air cleaner dirty or restricted Clean or renew element
firing after fuel is shut off
Oil leak on compressor side of Overhaul turbocharger
turbocharger where fitted
12123 1 02/07/2004
B.10.A / 69

CS540, CS640, CS520, CS660
IMPORTANT: Whenever effecting a repair, the cause of the problem must be identified and corrected to avoid
repeat failures. The following table lists problems and their possible causes with recommended remedial action.

Engine overheats Hose connection leaking or collapsed Tighten hose connection, replace hose if
damaged
Radiator cap defective or not sealing Replace radiator cap
Radiator leakage Repair/replace radiator
Improper fan belt adjustment Readjust fan belt
Radiator fins restricted Clean with compressed air
Faulty thermostat Replace thermostat
Internal engine leakage Check for source of leakage, replace
gasket or defective parts
Water pump faulty Overhaul water pump
Exhaust gas leakage into cooling system Replace cylinder head gasket, check head
for damage or distortion
Coolant aeration Tighten all connections and check coolant
level is correct. Ensure cylinder head
gasket has not blown
Cylinder head gasket improperly installed Replace cylinder head gasket
Hot spot due to rust and scale or clogged Reverse flush entire cooling system
water jackets
Obstruction to radiator air flow Remove the obstruction
Extended engine idling Do not allow engine to idle for long periods
Oil cooler tube blocked Clean
Radiator core tubes blocked Check free flow
Water temperature gauge Faulty temperature sender Replace sender switch
fails to reach normal
operating temperature
Incorrect or faulty thermostat Replace thermostat
Faulty water temperature gauge Replace temperature gauge
12123 1 02/07/2004
B.10.A / 70
Index
ENGINE - 10.A
Connecting rod and piston - Exploded view (B.10.A.47 - C.10.A.20) 17

CS540, CS640, CS520, CS660
Connecting rod and piston - General specification (B.10.A.47 - D.40.A.10) 10
CS540, CS640, CS520, CS660
Connecting rod and piston - Install (B.10.A.47 - F.10.A.15) 48
CS540, CS640, CS520, CS660
Connecting rod and piston - Overhaul (B.10.A.47 - F.10.A.40) 46
CS540, CS640, CS520, CS660
Connecting rod and piston - Remove (B.10.A.47 - F.10.A.10) 45
CS540, CS640, CS520, CS660
Crankshaft - General specification (B.10.A.43 - D.40.A.10) 8
CS540, CS640, CS520, CS660
Crankshaft - Install (B.10.A.43 - F.10.A.15) 33
CS540, CS640, CS520, CS660
Crankshaft - Overhaul (B.10.A.43 - F.10.A.40) 38
CS540, CS640, CS520, CS660
Crankshaft - Remove (B.10.A.43 - F.10.A.10) 32
CS540, CS640, CS520, CS660
Crankshaft Front seal - Install (B.10.A.43.01 - F.10.A.15) 36
CS540, CS640, CS520, CS660
Crankshaft Front seal - Remove (B.10.A.43.01 - F.10.A.10) 31
CS540, CS640, CS520, CS660
Cylinder block - Assemble (B.10.A.70 - F.10.A.20) 54
CS540, CS640, CS520, CS660
Cylinder block - Overhaul (B.10.A.70 - F.10.A.40) 51
CS540, CS640, CS520, CS660
Cylinder block - Rebore (B.10.A.70 - F.75.C.30) 53
CS540, CS640, CS520, CS660
Cylinder head - Assemble (B.10.A.72 - F.10.A.20) 61
CS540, CS640, CS520, CS660
Cylinder head - Disassemble (B.10.A.72 - F.10.A.25) 59
CS540, CS640, CS520, CS660
Cylinder head - General specification (B.10.A.72 - D.40.A.10) 10
CS540, CS640, CS520, CS660
Cylinder head - Overhaul (B.10.A.72 - F.10.A.40) 60
CS540, CS640, CS520, CS660
Cylinder head - Remove (B.10.A.72 - F.10.A.10) 56
CS540, CS640, CS520, CS660
Electronic control - Logical diagram (B.10.A.92 - C.20.B.72) 18
CS540, CS640, CS520, CS660
ENGINE - Compression test (B.10.A - F.40.A.35) 21
CS540, CS640, CS520, CS660
ENGINE - General specification (B.10.A - D.40.A.10) 7
CS540, CS640, CS520, CS660
ENGINE - Overhaul (B.10.A - F.10.A.40) 20
CS540, CS640, CS520, CS660
12123 1 02/07/2004
B.10.A / 71
ENGINE - Special tools (B.10.A - D.20.A.40) 6
CS540, CS640, CS520, CS660
ENGINE - Static description (B.10.A - C.30.A.20) 13
CS540, CS640, CS520, CS660
ENGINE - Torque (B.10.A - D.20.A.10) 5
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Flywheel - Install (B.10.A.50 - F.10.A.15) 50
CS540, CS640, CS520, CS660
Flywheel - Remove (B.10.A.50 - F.10.A.10) 49
CS540, CS640, CS520, CS660
Rear cover - Install (B.10.A.76 - F.10.A.15) 66
CS540, CS640, CS520, CS660
Rear cover - Remove (B.10.A.76 - F.10.A.10) 65
CS540, CS640, CS520, CS660
Timing gear - Install (B.10.A.45 - F.10.A.15) 43
CS540, CS640, CS520, CS660
Timing gear - Remove (B.10.A.45 - F.10.A.10) 40
CS540, CS640, CS520, CS660
Valve drive - Overhaul (B.10.A.40 - F.10.A.40) 27
CS540, CS640, CS520, CS660
Valve drive Camshaft - Install (B.10.A.40.44 - F.10.A.15) 25
CS540, CS640, CS520, CS660
Valve drive Camshaft - Overhaul (B.10.A.40.44 - F.10.A.40) 24
CS540, CS640, CS520, CS660
Valve drive Camshaft - Remove (B.10.A.40.44 - F.10.A.10) 22
CS540, CS640, CS520, CS660
12123 1 02/07/2004
B.10.A / 72
FUEL AND INJECTION SYSTEM - 20.A
CS540
CS640
CS520
CS660
12124 1 02/07/2004
B.20.A / 1
Contents
TECHNICAL DATA
FUEL AND INJECTION SYSTEM - Torque (B.20.A - D.20.A.10) 4

CS540, CS640, CS520, CS660
FUEL AND INJECTION SYSTEM - Special tools (B.20.A - D.20.A.40) 4
CS540, CS640, CS520, CS660
FUEL AND INJECTION SYSTEM - General specification (B.20.A - D.40.A.10) 5
CS540, CS640, CS520, CS660
Fuel shut-off
Fuel shut-off - General specification (B.20.A.13 - D.40.A.10) 5
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
FUEL AND INJECTION SYSTEM - Static description (B.20.A - C.30.A.20) 7

CS540, CS640, CS520, CS660
Fuel injection pump

Fuel injection pump - Static description (B.20.A.21 - C.30.A.20) 9
CS540, CS640, CS520, CS660
Fuel injector
Fuel injector - Static description (B.20.A.29 - C.30.A.20) 16
CS540, CS640, CS520, CS660
SERVICE
FUEL AND INJECTION SYSTEM - Bleed (B.20.A - F.35.A.25) 18

CS540, CS640, CS520, CS660
Fuel shut-off
Fuel shut-off - Remove (B.20.A.13 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Fuel shut-off - Install (B.20.A.13 - F.10.A.15) 20
CS540, CS640, CS520, CS660
Fuel shut-off Electrical shut-off - Check (B.20.A.13.81 - F.45.A.10) 21
CS540, CS640, CS520, CS660
Fuel injection pump

Fuel injection pump - Remove (B.20.A.21 - F.10.A.10) 22
CS540, CS640, CS520, CS660
Fuel injection pump - Install (B.20.A.21 - F.10.A.15) 24
CS540, CS640, CS520, CS660
Fuel injection pump - Timing check (B.20.A.21 - F.40.B.12) 27
CS540, CS640, CS520, CS660
12124 1 02/07/2004
B.20.A / 2
Fuel injection pump - Adjust (B.20.A.21 - F.45.A.01) 31
CS540, CS640, CS520, CS660
Fuel filter system

Fuel filter system Sediment filter - Adjust (B.20.A.24.21 - F.45.A.01) 32
CS540, CS640, CS520, CS660
Fuel injector
Fuel injector - Remove (B.20.A.29 - F.10.A.10) 33
CS540, CS640, CS520, CS660
Fuel injector - Disassemble (B.20.A.29 - F.10.A.25) 34
CS540, CS640, CS520, CS660
Fuel injector - Cleaning (B.20.A.29 - F.30.A.10) 35
CS540, CS640, CS520, CS660
Fuel injector - Assemble (B.20.A.29 - F.10.A.20) 37
CS540, CS640, CS520, CS660
Fuel injector - Test (B.20.A.29 - F.40.C.01) 38
CS540, CS640, CS520, CS660
Fuel injector - Install (B.20.A.29 - F.10.A.15) 40
CS540, CS640, CS520, CS660
Fuel lift pump

Fuel lift pump - Remove (B.20.A.34 - F.10.A.10) 42
CS540, CS640, CS520, CS660
Fuel lift pump - Install (B.20.A.34 - F.10.A.15) 43
CS540, CS640, CS520, CS660
Fuel line
Fuel line Low pressure - Remove (B.20.A.36.10 - F.10.A.10) 44
CS540, CS640, CS520, CS660
Fuel line Low pressure - Install (B.20.A.36.10 - F.10.A.15) 45
CS540, CS640, CS520, CS660
Fuel line High pressure - Remove (B.20.A.36.20 - F.10.A.10) 46
CS540, CS640, CS520, CS660
Fuel line High pressure - Install (B.20.A.36.20 - F.10.A.15) 48
CS540, CS640, CS520, CS660
12124 1 02/07/2004
B.20.A / 3
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
FUEL AND INJECTION SYSTEM - Torque (B.20.A - D.20.A.10)

CS540, CS640, CS520, CS660
Nm Lb. ft
Injector attachment bolts 23 17
Injector line nuts 24 18
Injection pump drive gear 30 23
Injection pump rear mounting bolts 38 28
Injection pump-to-front adaptor plate 38 28
Injection pump-to-gear drive bolts 67 50
Injection timing gear access cover 38 28
Leak-off tube banjo fitting bolts 9 7
Lift pump mounting to main junction pump, nuts, 3 8 6
FUEL AND INJECTION SYSTEM - Special tools (B.20.A - D.20.A.40)

CS540, CS640, CS520, CS660

Crankshaft timing pin 380000172 297672
Fuel injection pump timing pin 380000318 295005
Injector - hand pump tester Nozzle - 290284
test adaptor
Injector - cleaning kit 380000254 293671
Injector - splitting block 380000308 293760
Injector - splitting socket kit 380000309 293761
Injection pump drive gear puller (see 380000322 295042
fig.1)
10_10-3_01 1
Fuel injection pump drive gear puller (Local manufacture or Special tool No.295042)
1. Bolt 5/16-UNF x 2 in. (51 mm) with integral washer (3 bolts required)
2. Bolt 3/4x16-UNC x 2 in.(51 mm)
3. Three holes 0.375 in (9.5 mm) dia. on 2.2 in (56.87 mm) dia. equally spaced material of 0.394 in. (10
mm) Plate HRLC P&O Steel
(Prior tool numbers, where applicable, shown in brackets)
12124 1 02/07/2004
B.20.A / 4
FUEL AND INJECTION SYSTEM - General specification (B.20.A -

D.40.A.10)
CS540, CS640, CS520, CS660
Injection pump Mechanically controlled governor on Bosch P7100

Rated speed 2100 rpm
Low idle speed 1300 rpm
High idle speed 2205 rpm
Injection pump timing Set using fixed timing pins with engine at TDC
Fuel shut-off - General specification (B.20.A.13 - D.40.A.10)

CS540, CS640, CS520, CS660
Specifications: @ Rated voltage 12 V and rated temp. 20 ° C (68 ° F)

Pull current: 60 amps
Hold current: 0.87 amps
Pull rating: 93.4 N (21 lb) @ 25 mm (1 in) stroke
Hold rating: 178 N (40 lb)
Plunger stroke: 25.4 mm (1 in) maximum
Preliminary checks
1. Place the transmission in NEUTRAL and set the parking brake.
ZDF0809B 1
2. Check the battery voltage. Must be 12 volts or higher.

3. Verify that the solenoid plunger and pump control lever (1) move freely the full range, with no evidence
of binding or sticking.
4. With key switch in the “off" position, the control lever will be in the down position.
5. Turn the key switch to the “run" position. With the engine running the control lever will be in the “up" position.
6. Check the fuel shutoff solenoid linkage adjustment as described later. If readjusted, try restarting the engine
while observing the solenoid for proper function.
7. Inspect the electrical connections between the solenoid and harness to ensure good positive contacts, and
not sign of rust or corrosion.
Checking electrical feed
Ref Function
1 Ground
2 Pull
3 Hold
12124 1 02/07/2004
B.20.A / 5
1. Attach the positive lead of the voltmeter to the “hold coil terminal" of the solenoid. Attach the negative lead
of the voltmeter to the “common ground terminal" of the solenoid. Turn the ignition switch to the “RUN"
position. The voltmeter should read a minimum of 9 volts. Less than 9 volts indicates a bad circuit. Also,
there should be a 0.87 amp current draw.
70-150-2213 2
2. Attach the positive lead of the voltmeter to the “pull coil terminal" of the solenoid. Attach the negative lead of
the voltmeter to the “common ground terminal" of the solenoid.
Turn the key switch to the “RUN" position. A voltage of at least 9 volts should be present for approximately
two seconds, and the solenoid plunger should retract. Also there should be a 60.3 amp draw.
3. Attach the voltmeter leads between the solenoid “common ground" terminal and a good ground on the frame.
While the solenoid is in the “PULL" and “HOLD" positions, the voltmeter should read 0 volts. If there is
voltage, the ground circuit needs to be checked.
Verify linkage adjustments

1. Turn the key switch to the “RUN" position. The solenoid should fully retract.
70-150-2238 3
2. Remove the solenoid rod from the mechanical fuel shutoff lever.
3. Pull the mechanical fuel shutoff lever to the full “RUN" position.
4. It should now be possible to insert the fuel shutoff solenoid ball joint over the mechanical shutoff lever pin.
5. If necessary, adjust the fuel shutoff solenoid rod in order to accomplish step 4.
12124 1 02/07/2004
B.20.A / 6
FUEL AND INJECTION SYSTEM - Static description (B.20.A -

C.30.A.20)
CS540, CS640, CS520, CS660
The CNH 7.5 Liter engine is fitted with a mechanically controlled governor Bosch P7100 in line fuel injection pump.
Further explanation on the operation of this pump is given on the following pages.
BSD1882A 1
The fuel system irrespective of the type of fuel pump installed is fitted with a fuel prefilter (1) and water separator (2)
located beneath the fuel tank.
The primary purpose of this assembly is to remove water and solid contaminates from the fuel before the fuel enters
the gallery of the injection pump. The plunger and barrel assemblies (pumping elements) of the injection pump
are matched to each other with an accuracy of a few ten thousandths of an inch. Impurities of this size can cause
severe damage, or excessive wear, to the injection pump and injector assemblies.
ZDA5941B 2
A separate fuel filter (1) and water separator (2) is also installed immediately before the fuel enters the injection
pump.
ZDA6075A 3
12124 1 02/07/2004
B.20.A / 7
A fuel supply pump is also fitted to all pumps at the entry point into the injection pump fuel system. The supply pump
is mechanically driven by the injection pump camshaft. The purpose of the supply pump is to draw fuel from the
tank, and pressurize the fuel to a minimum of 1.4 bar (20 psi) in order to cause fuel to flow through the filter and
to provide sufficient pressure for pumping element filling. The supply pump housing also contains a sedimenter
assembly consisting of a clear bowl (2) and strainer screen (3). The clear bowl should be inspected for sediment
every 50 hours and cleaned every 600 hours.
On top of the supply pump is fitted a primer pump (1) which is used to prime the injection pump with fuel when the
filter element has been changed.
BDS1880A 4
12124 1 02/07/2004
B.20.A / 8
Fuel injection pump - Static description (B.20.A.21 - C.30.A.20)

CS540, CS640, CS520, CS660
The fuel injection pump, the heart of the fuel system, consists of a number of sub assemblies.On the mechanically
controlled pump the control rack which adjusts the fuel delivery through the pumping elements within the pump
is controlled by the flyweights and springs in the mechanical governor assembly which in turn is influenced by
the throttle lever, pump and engine speed.
ZDF0810A 1
Fuel shutoff solenoid
The purpose of the fuel shutoff solenoid (1) is to move the mechanical fuel shutoff lever to the “RUN" position when
the key switch is turned on, and to keep the lever in that position while the key switch remains in the “RUN" position.
When the key switch is turned “OFF," the solenoid is de-energized, and allows spring force within the governor
housing to move the mechanical shutoff lever to the “FUEL-OFF" position.
BSD1882B 2
Governor
The rear portion of the injection pump assembly houses the all-speed “RSV" mechanical governor. The governor
receives inputs from the following:
• Throttle control lever (4)
• Intake manifold pressure (2)
• Injection pump camshaft speed (3)
• Engine oil pressure, located on engine side of pump (not shown).
• Mechanical fuel shutoff lever (5) controlled by the fuel shutoff solenoid (1).
12124 1 02/07/2004
B.20.A / 9
70-150-2205 3
1 Governor housing 2 Starting spring

3 Throttle control lever 4 Governor housing
5 Shutoff idle stop 6 Tensioning lever
7 Guide lever 8 Governor spring
9 Auxiliary idle speed spring 10 Torque control & idle speed helical compression spring
11 Full load stop (fuel delivery) 12 Fulcrum lever
13 Guide bushing 14 Flyweight
15 Swivelling lever 16 Rocker
17 Strap 18 Control rack
Receiving these inputs, the governor, by moving the pumping element control rack (18) controls engine-off, excess
fuel for starting, minimum and maximum idle speeds, and any midrange speeds independent of load. A pair of
flyweights (14) are attached to the pump camshaft. The force of the flyweights increases with engine speed. The
force of the weights operates against that of the governor spring (8). The tension on the governor spring is varied
by the position of the throttle lever (3). Also contained within the governor housing is the starting spring (2). This
lightweight spring pulls the fuel control rack fully forward to the excess fuel position whenever the engine is not
running. As soon as the engine starts and the flyweights begin to generate force, the starting spring is overcome
and the rack returns to normal fuel delivery.
12124 1 02/07/2004
B.20.A / 10
Aneroid assembly
The aneroid assembly prevents excessive smoke under load by limiting maximum fuel delivery until the turbocharger
is providing sufficient air to effect clean combustion. An example of this operation would be starting a load out onto a
roadway, when the engine is idling, and throttle position and load are increased simultaneously.
70-150-2206 4
1. Headless setscrew
2. Plate washer
3. Governor cover
4. Strap
5. Fulcrum lever
6. Starting spring
7. Governor housing
8. Control rod
9. Bell crank
10. Control shaft
11. Guide bushing
12. Helical compression spring
13. Diaphragm
14. Charge air pressure
12124 1 02/07/2004
B.20.A / 11
The aneroid also contains a hydraulic activator (1) which is controlled by engine oil pressure, A. When there is no oil
pressure, B, the activator allows the control rack full travel to the excess fuel position. Without this feature, during
starting, fuel delivery would be extremely limited due to lack of turbocharger boost pressure.
70-150-2207 5
1. Hydraulic activator
2. Bell crank
3. Strap
Overflow valve assembly
The supply pump has a capacity of about twice that of the requirements of the high-pressure pumping elements.
This excess flow provides cooling and lubrication for the injection pump. Flow from the supply pump travels through
the filter element and then to the fuel gallery of injection pump, where it is available to fill the pumping elements.
The fuel must be pressurized in order to properly fill the pumping elements. The job of the overflow valve which is
housed within the body of the banjo bolt (1) is to maintain a pressure of approximately 1.5 bar (22 psi) in the fuel
gallery. Once that pressure is reached, the overflow valve opens and allows the excess fuel to return to the tank.
ZDF0809A 6
12124 1 02/07/2004
B.20.A / 12
High-pressure pumping elements

The high-pressure pumping elements, one for each engine cylinder, supply fuel at a pressure of approximately 240
bar (3500 psi) to the injectors. The pumping elements must provide the fuel in a precisely measured amount at the
proper time.Operation of the individual element is as follows:
70-150-2209 7
Fuel delivery cycle
Reference (A) - Bottom dead centre / Fuel in
Reference (B) - Spill port closure / Fuel pressurized
Reference (C) - Spill port opening / Fuel delivery ends
(A) With the plunger (1) at the bottom of the stroke, fuel flows into the barrel through the spill port (2) and fills the
space above the plunger.
(B) As the plunger (1) rises, the spill port in the barrel (3) is covered and the fuel is trapped. This is the point of port
closure. The continued upward movement of the plunger pressurizes the trapped fuel until the delivery valve (at
the base of each high-pressure injection line) is lifted from its seat. High-pressure fuel is transmitted through the
line to the injector and injection takes place through the injector nozzle.
(C) Injection stops when the upper edge of the helix (4) uncovers the lower edge of the spill port. Pressure escapes
to the fuel gallery. The drop in pressure causes the injector to close and injection to stop. After fuel delivery ceases,
the plunger continues to the top of the stroke and is returned by a spring for the next cycle.
10_10-3_14 8
12124 1 02/07/2004
B.20.A / 13
Because the end of delivery is reached when the helix on the plunger uncovers the spill port (1) the amount
of fuel delivered is varied by turning the pump plunger as shown at D. If the plunger is turned until the vertical
groove completely uncovers the spill port as shown at E, during the entire lift of the plunger, there will be no fuel
delivered to the engine. This is because injection pressure cannot be reached, thereby shutting off the engine.The
plungers are rotated by a control rack splined to each plunger. Rack movement is determined by the control
rod, actuated by the governor.
10_10-3_15 9
Fuel delivery and timing during starting
The plungers (1) are equipped with starting grooves (2) on their crown. The purpose of this groove is to assist in
starting the engine by providing both excess fuel and slightly retarded timing. When the key switch is turned
on, the fuel shutoff solenoid retracts, moving the mechanical shutoff lever to the “RUN" position. The starting
spring in the governor housing pulls the control rack fully forward, beyond the normal maximum fuel position. This
aligns the starting groove with the spill port. With the starting groove aligned with the spill port, there is a delay in
spill port closure which, in turn, delays the start of injection. Note also that there is no helix in this region of the
plunger, so once injection begins, it is not cut off until the plunger reaches the end of its stroke. This provides a
very large amount of fuel to aid starting.
10_10-3_16 10
12124 1 02/07/2004
B.20.A / 14
Delivery valves
A delivery valve is located above each plunger. The delivery valve serves as a one-way valve which allows fuel
under injection pressure to move into the high pressure tubes and prevents fuel from coming back. The valve also
serves to rapidly reduce pressure in the injection line once pressure from the plunger has ceased. Rapid pressure
reduction is required to ensure the injector valve snaps shut to prevent fuel “dribble," a condition which can cause
carbon formation on the injector tip.
(a) Valve closed
(b) Valve open during fuel delivery
Components are identified as follows:
10_10-3_17 11
1. Delivery valve holder 2. Spring

3. Valve 4. Valve seat
5. Valve holder
12124 1 02/07/2004
B.20.A / 15
Fuel injector - Static description (B.20.A.29 - C.30.A.20)

CS540, CS640, CS520, CS660
The job of the injector assembly is to atomize the fuel in order to facilitate proper combustion. The injector must
cleanly deliver the fuel into the combustion chamber with a good spray pattern. There must also be a “crisp" start,
and end of injection with no drips either before or after the injection cycle.
The nozzle is housed within a nozzle holder. In order to properly place the fuel charge into the combustion chamber,
dowel pins orient the nozzle within the holder, and a clamp ring orients the holder within the engine cylinder head.
70-150-2210 1
Operation of the injection nozzle is as follows:
1. High pressure inlet line

2. Edge-type filter
3. Pressure channel
4. Intermediate disc
5. Nozzle-retaining nut
6. Union nut for fuel-injection tubing
7. Holder body
8. Leak-off port
9. Pressure-adjusting shims
10. Pressure spring
11. Pressure spindle
12. Locating pins (locating the nozzle)
13. Injection nozzle
12124 1 02/07/2004
B.20.A / 16
The high-pressure line delivers the fuel charge from the injection pump. Fuel enters the inlet and passes through the
edge-type filter. Coarse foreign particles are retained by the filter.
A passage routes fuel through the nozzle holder to the nozzle valve. The nozzle valve is lifted off its seat by the
high-pressure inlet fuel (1) acting on the annulus in the valve.
When the nozzle valve opens, a definite quantity of fuel (determined by the injection pump output for each plunger
stroke) is forced out through the orifices. The fuel becomes finely atomized as it is sprayed into the combustion
chamber at high velocity. Once fuel flow from the pump ceases, the spring pressure forces the needle valve
back onto its seat via the spindle and needle valve stem. Fuel dribble should not occur, as might happen if the
nozzle showed excessive wear.
The nozzle assembly is lubricated by a small amount of fuel which seeps between the lapped surfaces of the
nozzle and valve which accumulates around the spring.
The leakage fuel (2) is routed out the nozzle holder through a leak-off connector and returned back to the fuel tank.
70-150-2211 2
Low-pressure fuel lines
The purpose of the low-pressure fuel lines (3) is to carry fuel from the tank to the injection pump gallery and to return
excess fuel from the pump and injectors (2) to the tank.
High-pressure fuel lines
The purpose of the high-pressure fuel lines (1) is to carry fuel, under high pressure, from the injection pump to the
injector assemblies. These lines are a precise length to provide proper fuel delivery. For this reason, always use
the correct line if replacement is required.
ZDF0810B 3
12124 1 02/07/2004
B.20.A / 17
FUEL AND INJECTION SYSTEM - Bleed (B.20.A - F.35.A.25)

CS540, CS640, CS520, CS660
It may be necessary after injection pump removal or injector removal to purge the high pressure lines of air to
allow the engine to start.
If the engine fails to start after several turns bleed the system using the following procedure:
1. ’Crack’ open in turn, starting at injector number 1,

the nut (1) of each high pressure lines. Crank the
engine on the starter motor to expel the air. With
the aid of an assistant, tighten the injector nuts as
the engine begins to fire.
WARNING
Z031 - Wear safety glasses or a protective face shield
when working with high-pressure fuel. Keep eyes and
hands away from nozzle spray. Fuel spraying from
the nozzle under high pressure can penetrate the
skin and cause blood poisoning. Medical attention
should be provided immediately in the event of skin
penetration.Take extreme care of moving belts and 10_10-3_39 1
pulleys.
12124 1 02/07/2004
B.20.A / 18
Fuel shut-off - Remove (B.20.A.13 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Disconnect the wire connector from the fuel shutoff

solenoid.
70-150-2243 1
2. Remove the solenoid plunger linkage from the

pump run/stop lever (1).
70-150-2242 2
3. Remove the two cap screws which hold the fuel

shutoff solenoid to the engine block.
12124 1 02/07/2004
B.20.A / 19
Fuel shut-off - Install (B.20.A.13 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Attach the fuel shutoff solenoid to the engine block

with two cap screws.
2. Torque cap screw between 5 - 7 Nm (42 - 60 lb ft).
3. Attach the solenoid plunger linkage to the pump
run/stop lever (1).
70-150-2242 1
4. Connect the wire connector to the fuel shutoff

solenoid (1).
70-150-2243 2
5. Check the fuel shutoff solenoid for proper

adjustment.
6. Start and stop the engine to check for proper
operation of the solenoid.
12124 1 02/07/2004
B.20.A / 20
Fuel shut-off Electrical shut-off - Check (B.20.A.13.81 - F.45.A.10)

CS540, CS640, CS520, CS660
1. In cases where the proper function of the fuel

shutoff solenoid is suspect, the following steps
will diagnose both the solenoid and the electrical
feed to the pull coil terminal, hold coil terminal, and
common ground terminal.
Ground (1)
Pull (2)
Hold (3)
70-150-2213 1
12124 1 02/07/2004
B.20.A / 21
Fuel injection pump - Remove (B.20.A.21 - F.10.A.10)

CS540, CS640, CS520, CS660
IMPORTANT: Internal repairs to the fuel injection pump must be accomplished through a Bosch authorized Diesel
Service Dealer (DSD). The only adjustment that can be accomplished to the pump on-vehicle is low speed idle
adjustment.
NOTE: Before removing any fuel lines, clean the exterior of the fuel injection pump with clean fuel oil or solvent to
help prevent the entry of dirt or other contamination. The area can be steam cleaned (which is probably the best
method of getting the area clean), but it can only be done when the engine is cold and shut off.
IMPORTANT: Do not wash or steam clean the engine while it is running or still hot from running. Serious damage to
the injection pump could occur.
1. Disconnect the negative battery cables from the
battery and/or batteries.
2. Perform the injection pump timing check described
previously and install the injection pump timing pin
295005, refer to ENGINE - Special tools (B.10.A
- D.20.A.40).
10_10-3_30_12 1
3. Remove pump drive gear retaining bolts (1)

retaining plate (2) and gear (3).
70-150-2224 2
4. Disconnect all pipe work and fuel lines. Cap all

openings to prevent dirt contamination.
CAUTION
Z030 - Use two wrenches on these high pressure lines
to prevent distorting or rotating the pumping element.
12124 1 02/07/2004
B.20.A / 22
5. Remove the tube assembly and disconnect the

throttle linkage.
ZDF0810A 3
6. Remove the four retaining nuts and withdraw the

pump from the engine.
BSD1882A 4
12124 1 02/07/2004
B.20.A / 23
Fuel injection pump - Install (B.20.A.21 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Using 29 mm socket (1-1/8 in) rotate crankshaft to

top dead centre (TDC) with number 1 cylinder firing
(on compression stroke).
NOTE: If engine is at TDC with number 1 cylinder on
exhaust stroke the pump timing will be 180 ° out of phase.
10_10-3_24 1
2. Insert the crankshaft timing pin 297672 into the

side of the block. Refer to FUEL AND INJECTION
SYSTEM - Special tools (B.20.A - D.20.A.40).
BSC1304A 2
3. 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’.
BSC1306A 3
12124 1 02/07/2004
B.20.A / 24
4. 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.
BSC1305A 4
5. With the pump on the bench, rotate the injection

pump clockwise until the threaded hole in the pump
drive flange aligns with the pump timing plate.
Screw the injection pump timing pin 295005 into the
pump. Refer to FUEL AND INJECTION SYSTEM -
P393-E-48 5
6. Refit pump onto engine and tighten the four retaining

nuts to a torque between 27 - 34 Nm (20 - 25 lb ft).
BSD1847A 6
7. Refit pump gear and plate.

Tighten gear retaining bolts to a torque between 54
- 75 Nm (40 - 55 lb ft).
Remove timing pins from pump and side of engine
block.
10_10-3_30_12 7
12124 1 02/07/2004
B.20.A / 25
8. Refit injection pump timing gear cover and drive belt.
10_10-3_22 8
12124 1 02/07/2004
B.20.A / 26
Fuel injection pump - Timing check (B.20.A.21 - F.40.B.12)

CS540, CS640, CS520, CS660
If a fuel related concern is identified check the injection pump timing before proceeding with any other disassembly.
1. Remove all necessary hardware and components in

order to gain access to the front timing cover.
2. Remove the alternator, water pump and
air-conditioning drive belt.
ZDA6251A 1
3. To remove the belt release the tension applied by

the belt tensioning pulley.
10_10-3_22 2
4. Remove injection pump timing cover.
10_10-3_23 3
12124 1 02/07/2004
B.20.A / 27
5. Using 29 mm (1-1/8 in) socket rotate crankshaft to

top dead centre (TDC) with number 1 cylinder firing.
10_10-3_24 4
6. When engine is at TDC the threaded hole in the

injection pump drive flange aligns with the pump
timing plate.
10_10-3_25 5
7. 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.
BSD1542B 6
8. Insert the crankshaft timing pin 297672 into the

side of the block. Refer to FUEL AND INJECTION
SYSTEM - Special tools (B.20.A - D.20.A.40).
BSC1304A 7
12124 1 02/07/2004
B.20.A / 28
9. 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’.
BSC1306A 8
10. 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.
BSC1305A 9
11. Check that the injection pump timing pin Tool no

295005 will screw into the pump hub. Refer to
FUEL AND INJECTION SYSTEM - Special tools
(B.20.A - D.20.A.40).
IMPORTANT: The engine must never be rotated while
the timing pin is installed.
10_10-3_30_12 10
12. If the pin engages in the pump timing plate (inset,

Fig.11) when the crankshaft is at TDC the pump
timing is correct.
12124 1 02/07/2004
B.20.A / 29
13. If pump timing is incorrect and timing pin can not

be screwed into pump, remove pump timing gear,
install timing pin 295005 Refer to into pump and
refit timing gear.
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.
P393-E-48 11
12124 1 02/07/2004
B.20.A / 30
Fuel injection pump - Adjust (B.20.A.21 - F.45.A.01)

CS540, CS640, CS520, CS660
NOTE: Before proceeding, make certain that the throttle controls are properly adjusted.
NOTE: This is the only adjustment that can be done to the fuel injection pump by a technician NOT authorized by
Bosch.
1. Ensure the throttle control is in the full idle position.
70-150-2236 1
2. Back off the low idle auxiliary adjustment screw (2).

3. Adjust the low idle screw (1) so that the engine
speed is 1290 rpm +/- 10.
4. Thread the low idle auxiliary screw in until low idle
speed reaches 1310 rpm +/- 10.
5. Run the throttle up to high idle and then back down
to the low idle position to confirm correct speed
settings.
12124 1 02/07/2004
B.20.A / 31
Fuel filter system Sediment filter - Adjust (B.20.A.24.21 - F.45.A.01)

CS540, CS640, CS520, CS660
1. Inspect supply pump fuel bowl for sediment every

50 hours and clean, or replace, the screen in the
sedimenter if required.
2. On reassembly ensure the bowl is sealing well
against the housing.
70-150-178 1
1 Fuel bowl 2 Fuel supply pump

3 O-ring 4 Sedimenter
5 Screen
12124 1 02/07/2004
B.20.A / 32
Fuel injector - Remove (B.20.A.29 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Ensure the areas around the injectors and fuel

pump are clean prior to disassembly.
Remove the injector high pressure lines (1).
Remove banjo bolts (3) holding leak-off line (4) to
the fuel injector (2). Start at No. 1 injector and work
back.
Remove leak off line and discard the two copper
washers (one either side of the banjo fitting). New
washers must be used for reassembly.
70-150-209 1
2. Remove the injector retaining bolts and washers (1)

and hold-down clamp (2).
Turn the injector (3) clockwise to loosen it, then
remove from the head.
Remove the copper sealing washer (4) from the
injector. If the washer is not on the injector it has
remained in the head and must be extracted.
Discard the copper washers.
Make sure the injector cavity is clean of carbon
before installing new copper washer.
Remove the cork dust seal (5) from the injector.
NOTE: Each injector should have a cork seal under the
retaining flange, remove the seal from either the cylinder
head or injector and discard. New seals should always 70-150-210 2
be installed on reassembly.
12124 1 02/07/2004
B.20.A / 33
Fuel injector - Disassemble (B.20.A.29 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Place the injector in a holding fixture, Tool

No.293760, with the nozzle uppermost. Do not
clamp the injector body in a vice. Use socket tool,
295008, (kit 293761), ENGINE - Special tools
(B.10.A - D.20.A.40), to loosen the nozzle retaining
nut.
Remove the nozzle retaining nut, complete with the
nozzle body, needle valve and the dowelled adaptor
plate.
TA6010117 1
2. Remove the injector body from the holding fixture,

invert and carefully remove the spring seat, spring
and adjustment shims. To avoid damage, place all
dismantled components in suitable baths of clean
fuel oil.
NOTE: To prevent corrosion of injector components after
cleaning, rinse in clean fuel oil and place in a suitable
bath of clean fuel oil.
TA6010118 2
12124 1 02/07/2004
B.20.A / 34
Fuel injector - Cleaning (B.20.A.29 - F.30.A.10)

CS540, CS640, CS520, CS660
1. Clean the injector body by soaking in a carbon

solvent and brushing with a brass wire brush.
Inspect the body for damaged threads and pressure
face, making sure the holes in the injector nozzle
are thoroughly clean with no signs of corrosion or
pitting.
Clean the spring and spring seat using a brass wire
brush and check for scoring, pitting or corrosion.
Clean the dowelled adaptor plate using a brass wire
brush. Inspect the plate for loose or bent dowels, a
damaged pressure face or corrosion.
TA6010113 1
2. Clean the needle valve and body by soaking in

a carbon solvent and brushing with a brass wire
brush. Using the tools included in the Injector
Nozzle Cleaning Kit, Tool No.293671, refer to
ENGINE - Special tools (B.10.A - D.20.A.40),
clean the nozzle as follows:
NOTE: If the needle valve is in any way damaged or blued,
it must be discarded and a new matched needle valve and
nozzle body assembly obtained. It is not possible to grind
or lap the three special angles on the valve point.
10_10-3_56 2
3. Clean the spray holes with a nozzle cleaning wire

held in a pin vise so that it protrudes for only 1.5
mm (0.06 in.), thereby giving maximum resistance
to bending. Insert the wire into each hole, pushing
and rotating gently until each hole is cleared.
10_10-3_57 3
12124 1 02/07/2004
B.20.A / 35
4. Clean the needle valve seat using the valve seat

scraper by rotating and pushing the tool onto the
valve seating.
Clean the fuel port using the fuel port scraper. Insert
the scraper into the port, press hard against the side
of the cavity and rotate to clear all carbon deposits
from this area.
10_10-3_58 4
5. Use a Reverse Flush Nozzle Adaptor on the injector

tester and reverse flush the nozzle to remove the
carbon loosened during cleaning, Step 2.
After flushing the nozzle, polish the valve seat by
placing a very small amount of tallow on the end of
a polishing stick and rotate in the nozzle.
10_10-3_59 5
6. Clean the top of the needle valve using a needle

valve scraper.
Clean the nozzle retaining nut using a brass wire
brush and check to see that the threads are not
damaged and are free from carbon deposits.
10_10-3_60 6
12124 1 02/07/2004
B.20.A / 36
Fuel injector - Assemble (B.20.A.29 - F.10.A.20)

CS540, CS640, CS520, CS660
To set the nozzle opening pressure, connect the injector to the test rig as described in "Testing’’ and add or subtract
shims from the spring until the specified initial setting opening pressure of between 280-300 bar (4060-4350
psi) is achieved.
1. Make sure all parts are absolutely clean and

undamaged prior to reassembly. Rinse all parts in
clean fuel oil and assemble the components while
still wet.
Place the shims, spring and spring seat into the
injector body bore. Place the injector body into the
holding fixture.
Assemble the needle valve into the nozzle body and
then position the dowelled adaptor plate onto the
nozzle body. Insert this assembly into the nozzle
retaining nut.
TA6010113_1 1
2. Carefully assemble the dowelled adaptor plate and

the nozzle retaining nut assembly onto the injector
body, tighten the retaining nut to 45 Nm (33 lb ft)
torque.
12124 1 02/07/2004
B.20.A / 37
Fuel injector - Test (B.20.A.29 - F.40.C.01)

CS540, CS640, CS520, CS660
During the Nozzle Opening Pressure and Spray Pattern Tests, collect the spray in a container partly filled with
rags to absorb the spray.
When conducting the Nozzle Seat Leakage Test, release the injector tester pump pressure before touching the
nozzle tip with a sheet of blotting paper.
WARNING
Z024 - The spray from a fuel injector tester can pierce human skin with fatal results. When an injector is
spraying, the nozzle holder should be turned away from the operator and any other persons.
WARNING
Z025 - The spray is flammable make sure no open flames are in the area of the tester and do not generate
excessive vapor.
1. Fill the injector tester, Tool No.290284, refer to

ENGINE - Special tools (B.10.A - D.20.A.40), with
a calibrating type fuel oil and leave the filler cap
loose to prevent a vacuum forming during testing.
10_10-3_49 1
2. Prime the tester until oil is emitted from the tester

line, then connect the injector.
3. Make sure the knob on the right-hand side of the
tester is screwed in to prevent the gauge being
over-pressurized if the injector nozzle is blocked.
4. Pump the tester and check the nozzle is free to
open. Open the pressure gauge valve and begin
injector testing. If the nozzle is blocked or the
needle jammed, disassemble the injector.
5. Nozzle Opening Pressure Setting - Slowly pump the
injector tester and observe the pressure at which the
needle valve lifts and fuel is injected from the nozzle
tip. The minimum acceptable opening pressure is
280 bar (4060 psi) and the specification for new
injectors is 300 bar (4350 psi). If the opening
pressure is below 280 bar (4060 psi) reset to
specification by adding shims to the injector spring
as shown in the injector disassembly procedure.
10_10-3_50 2
12124 1 02/07/2004
B.20.A / 38
6. Spray pattern - Pump the tester rapidly (80 to 90

strokes per/min.) and observe the spray pattern
from the holes. An atomized spray (1) free from
distortion and irregular streaks of fuel should be
observed. A non uniform or split stream spray (2)
is not acceptable.
NOTE: The tester is not regarded as providing a suitable
test for atomization under working conditions, but gives
an indication of the working of the nozzle.
10_10-3_51 3
7. Nozzle seat leakage - Wipe the nozzle tip dry

and apply a pressure 10 bar (145 psi) below the
opening pressure. The nozzle tip and bottom face
must remain essentially dry and there must be no
tendency for blobs of fuel to collect or drip. A slight
dampness can be ignored. If there is any leakage
from the nozzle seat, the nozzle assembly must be
cleaned or replaced.
10_10-3_52 4
8. Nozzle back leakage - Apply a pressure 10 bar (145

psi) below the opening pressure, then release the
handle and time the pressure drop. The pressure
should drop 100-150 bar (1450-2175 psi) in 5 - 45
seconds. If below 5 seconds, the nozzle assembly
must be replaced. If above 45 seconds, check
for carbon on the valve and/or blocked back leak
drillings.
NOTE: If the injectors meet the tests carried out then refit
the injectors to the engine.
12124 1 02/07/2004
B.20.A / 39
Fuel injector - Install (B.20.A.29 - F.10.A.15)

CS540, CS640, CS520, CS660
The installation is the reverse of the removal procedure noting the following points.
1. Install a new cork seal to the underside of the

retaining flange.
Install a new copper washer on the end of the
injector.
70-150-210 1
2. Install the injector.
10_10-3_62 2
3. Install the retaining bolts and washers. Torque the

bolts evenly to 22 Nm (17 lb ft.).
NOTE: Be sure to install the clamp with the raised side
facing up.
10_10-3_63 3
4. Install the leak-off line using new copper washers

(6), Fig.1, on either side of the banjo fitting.
5. Torque the leak-off line retaining bolt (7) to 4.5 Nm
(40 lb ft).
6. Install the high pressure line and tighten the
connector to 24 Nm (18 lb ft.).
7. Repeat the process on the remaining injectors.
12124 1 02/07/2004
B.20.A / 40
8. It may be necessary to bleed the fuel system of air

in order to start the engine. Refer to FUEL AND
INJECTION SYSTEM - Bleed (B.20.A - F.35.A.25).
12124 1 02/07/2004
B.20.A / 41
Fuel lift pump - Remove (B.20.A.34 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the fuel inlet and outlet lines from the lift
pump.
BSD1880B 1
2. Remove the three nuts which mount the lift pump to

the fuel injection pump.
3. Remove the lift pump.
4. Clean all old gasket material from the lift pump and
the fuel injection pump mating surfaces.
5. If required, remove the fuel inlet tube fitting. Discard
the seal ring.
12124 1 02/07/2004
B.20.A / 42
Fuel lift pump - Install (B.20.A.34 - F.10.A.15)

CS540, CS640, CS520, CS660
1. If needed, rotate the crankshaft so the low side of

the fuel injector pump camshaft lobe is facing out.
BSD1880B 1
2. Install the lift pump gasket onto the fuel injection

pump. Make sure the gasket mating surfaces are
clean.
3. Install the lift pump onto the fuel injection pump.
4. Place the mounting nuts on the studs and tighten
between 7 - 9 Nm (5 - 7 lb ft).
5. Start and stop the engine to check proper operation
of the solenoid.
6. Install the inlet and outlet lines on the fuel lift
pump. Tighten until the coupling contacts the body
shoulder 7 Nm (5 lb ft).
7. Loosen the inlet line to the fuel injection pump.
Operate the hand primer on the lift pump to displace
any air that might be in the fuel lines. Tighten the
connection.
8. Start the engine and run it for approximately two
minutes. Observe all connections for fuel leaks.
9. Stop the engine and check for oil leakage from the
lift pump gasket.
12124 1 02/07/2004
B.20.A / 43
Fuel line Low pressure - Remove (B.20.A.36.10 - F.10.A.10)

CS540, CS640, CS520, CS660
NOTE: Before removing any fuel lines, clean the exterior of the fuel lines with fuel oil or solvent to prevent the entry
of dirt into the fuel system when the fuel lines are removed. Blow dry with compressed air.
1. Disconnect the battery ground cables from all
batteries.
ZDF0810B 1
2. Disconnect and remove the low-pressure fuel line

assembly (3) including the filter. Cap the lines as
they are removed. Inspect the rubber spacers at the
ends of the lines for distortion. Replace as required.
3. If required, remove the banjo bolt which connects
the pump return tube (2). Remove and discard the
seals on the banjo bolt.
12124 1 02/07/2004
B.20.A / 44
Fuel line Low pressure - Install (B.20.A.36.10 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the low-pressure fuel lines and filter assembly

back on the engine. Make sure the tubes have fully
seated into their correct fittings before tightening the
retaining nuts to specification.
ZDF0810B 1
2. If removed, install the banjo bolt (1) with new seals

to the pump return tube. Tighten the valve between
30 - 40 Nm (22 - 30 lb ft).
ZDF0809A 2
3. If removed, install the fuel inlet fitting with a new

seal to the pump. Tighten between 30 - 40 Nm (22
- 30 lb ft.).
4. Connect the battery ground cable to both batteries.
5. Run the engine and check for leaks.
12124 1 02/07/2004
B.20.A / 45
Fuel line High pressure - Remove (B.20.A.36.20 - F.10.A.10)

CS540, CS640, CS520, CS660
70-150-2249 1
In the case of damage to a single fuel injection line, do not attempt to remove it by itself. Always remove the fuel
injection lines as a set. It is much easier to get them off the engine, and it helps to prevent damaging the injection
lines that are still good.
1. Remove the low-pressure fuel lines following the

procedures described in this chapter.
2. Disconnect the fuel injection lines at the injectors.
As the line is removed, use a plastic cap to prevent
the entry of dirt into the system.
3. Disconnect the fuel lines at the fuel injection pump
(3). Cap each line and pumping element as the
line is removed to prevent the entry of dirt into the
system. Use two wrenches on the lines to prevent
accidental rotation of the pumping element.
4. Detach the bracket (1) holding the fuel injection line
assembly to the intake manifold.
5. Carefully wiggle the fuel injection lines (2) out from
under the intake manifold and remove them from
the engine. Start from the back and move toward
the front of the engine.
12124 1 02/07/2004
B.20.A / 46
6. Once removed from the engine, individual fuel lines

can be removed from the assembly for replacement.
Keep in mind when ordering parts that each line
is different and cannot be interchanged; therefore,
order lines individually for the particular cylinder the
line goes to.
12124 1 02/07/2004
B.20.A / 47
Fuel line High pressure - Install (B.20.A.36.20 - F.10.A.15)

CS540, CS640, CS520, CS660
70-150-2249 1
1. Make sure the clamps (4) holding lines together are

tight.
NOTE: High-pressure fuel lines must be installed as a set.
It is much easier than installing them individually.
2. Wiggle the high-pressure fuel injection lines into
position on the engine. Start from the back and go
toward the front of the engine.
3. Install the injection lines (2) onto the injection pump
(3) and tighten the nuts to 22-27 Nm (16-20 lb ft.).
Tighten the bracket (1) holding the high-pressure
fuel lines to the intake manifold. Use two wrenches
to tighten the lines to prevent accidental rotation
of the pumping element.
70-150-2232 2
12124 1 02/07/2004
B.20.A / 48
4. Connect the high fuel injection lines to the fuel

injectors one at a time starting with cylinder No. 1.
NOTE: Do not remove the caps from the fuel lines or
components until they are to be connected. This will help
prevent the entry of dirt into the system.
5. Tighten the fuel injection line to injector nuts
between 22 - 27 Nm (16 - 20 lb ft.).
6. Install the low-pressure fuel lines and filter
assembly back on the engine. Tighten the nuts to
specification.
7. Connect the battery ground cables to both batteries.
8. Run the engine and check for leaks.
9. If necessary, purge the high-pressure fuel lines
of air by loosening the connector one-half to one
turn and cranking the engine until solid fuel, free
from bubbles, sprays from the connection. Refer to
FUEL AND INJECTION SYSTEM - Bleed (B.20.A -
F.35.A.25).
WARNING
Z031 - Wear safety glasses or a protective face shield
when working with high-pressure fuel. Keep eyes and
hands away from nozzle spray. Fuel spraying from
the nozzle under high pressure can penetrate the
skin and cause blood poisoning. Medical attention
should be provided immediately in the event of skin
penetration.Take extreme care of moving belts and
pulleys.
12124 1 02/07/2004
B.20.A / 49
Index
FUEL AND INJECTION SYSTEM - Bleed (B.20.A - F.35.A.25) 18

CS540, CS640, CS520, CS660
FUEL AND INJECTION SYSTEM - General specification (B.20.A - D.40.A.10) 5
CS540, CS640, CS520, CS660
FUEL AND INJECTION SYSTEM - Special tools (B.20.A - D.20.A.40) 4
CS540, CS640, CS520, CS660
FUEL AND INJECTION SYSTEM - Static description (B.20.A - C.30.A.20) 7
CS540, CS640, CS520, CS660
FUEL AND INJECTION SYSTEM - Torque (B.20.A - D.20.A.10) 4
CS540, CS640, CS520, CS660
Fuel filter system Sediment filter - Adjust (B.20.A.24.21 - F.45.A.01) 32
CS540, CS640, CS520, CS660
Fuel injection pump - Adjust (B.20.A.21 - F.45.A.01) 31
CS540, CS640, CS520, CS660
Fuel injection pump - Install (B.20.A.21 - F.10.A.15) 24
CS540, CS640, CS520, CS660
Fuel injection pump - Remove (B.20.A.21 - F.10.A.10) 22
CS540, CS640, CS520, CS660
Fuel injection pump - Static description (B.20.A.21 - C.30.A.20) 9
CS540, CS640, CS520, CS660
Fuel injection pump - Timing check (B.20.A.21 - F.40.B.12) 27
CS540, CS640, CS520, CS660
Fuel injector - Assemble (B.20.A.29 - F.10.A.20) 37
CS540, CS640, CS520, CS660
Fuel injector - Cleaning (B.20.A.29 - F.30.A.10) 35
CS540, CS640, CS520, CS660
Fuel injector - Disassemble (B.20.A.29 - F.10.A.25) 34
CS540, CS640, CS520, CS660
Fuel injector - Install (B.20.A.29 - F.10.A.15) 40
CS540, CS640, CS520, CS660
Fuel injector - Remove (B.20.A.29 - F.10.A.10) 33
CS540, CS640, CS520, CS660
Fuel injector - Static description (B.20.A.29 - C.30.A.20) 16
CS540, CS640, CS520, CS660
Fuel injector - Test (B.20.A.29 - F.40.C.01) 38
CS540, CS640, CS520, CS660
Fuel lift pump - Install (B.20.A.34 - F.10.A.15) 43
CS540, CS640, CS520, CS660
Fuel lift pump - Remove (B.20.A.34 - F.10.A.10) 42
CS540, CS640, CS520, CS660
Fuel line High pressure - Install (B.20.A.36.20 - F.10.A.15) 48
CS540, CS640, CS520, CS660
Fuel line High pressure - Remove (B.20.A.36.20 - F.10.A.10) 46
CS540, CS640, CS520, CS660
Fuel line Low pressure - Install (B.20.A.36.10 - F.10.A.15) 45
CS540, CS640, CS520, CS660
12124 1 02/07/2004
B.20.A / 50
Fuel line Low pressure - Remove (B.20.A.36.10 - F.10.A.10) 44
CS540, CS640, CS520, CS660
Fuel shut-off - General specification (B.20.A.13 - D.40.A.10) 5
CS540, CS640, CS520, CS660
Fuel shut-off - Install (B.20.A.13 - F.10.A.15) 20
CS540, CS640, CS520, CS660
Fuel shut-off - Remove (B.20.A.13 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Fuel shut-off Electrical shut-off - Check (B.20.A.13.81 - F.45.A.10) 21
CS540, CS640, CS520, CS660
12124 1 02/07/2004
B.20.A / 51
12124 1 02/07/2004
B.20.A / 52
ENGINE COOLANT SYSTEM - 50.A
CS540
CS640
CS520
CS660
12126 1 02/07/2004
B.50.A / 1
Contents
TECHNICAL DATA
ENGINE COOLANT SYSTEM - Torque (B.50.A - D.20.A.10) 3

CS540, CS640, CS520, CS660
ENGINE COOLANT SYSTEM - General specification (B.50.A - D.40.A.10) 3
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
ENGINE COOLANT SYSTEM - Static description (B.50.A - C.30.A.20) 4

CS540, CS640, CS520, CS660
SERVICE
Thermostat
Thermostat - Remove (B.50.A.18 - F.10.A.10) 6
CS540, CS640, CS520, CS660
Thermostat - Check (B.50.A.18 - F.40.A.11) 7
CS540, CS640, CS520, CS660
Thermostat - Install (B.50.A.18 - F.10.A.15) 8
CS540, CS640, CS520, CS660
Water pump
Water pump - Remove (B.50.A.20 - F.10.A.10) 9
CS540, CS640, CS520, CS660
Water pump - Disassemble (B.50.A.20 - F.10.A.25) 10
CS540, CS640, CS520, CS660
Water pump - Check (B.50.A.20 - F.40.A.11) 12
CS540, CS640, CS520, CS660
Water pump - Assemble (B.50.A.20 - F.10.A.20) 13
CS540, CS640, CS520, CS660
Water pump - Install (B.50.A.20 - F.10.A.15) 16
CS540, CS640, CS520, CS660
DIAGNOSTIC
Rotary screen
Rotary screen Motor - Open circuit (B.50.A.58.01 - G.30.B.50) 17
CS540, CS640, CS520, CS660
12126 1 02/07/2004
B.50.A / 2
POWER PRODUCTION - ENGINE COOLANT SYSTEM
ENGINE COOLANT SYSTEM - Torque (B.50.A - D.20.A.10)

CS540, CS640, CS520, CS660
TIGHTENING TORQUES
Description Nm Lb.ft
Thermostat housing 18 24
Temperature senders 15 20
Tensioner pulley bolt 40 54
Tensioner front cover 40 54
Idler pulleys 40 54
Pump connector to block 18 24
Water pump to block 48 65
Fan blade to support body 17 23
Fan blade to clutch support body 78 105
ENGINE COOLANT SYSTEM - General specification (B.50.A -

D.40.A.10)
CS540, CS640, CS520, CS660
THERMOSTAT
Opening temperature 79-83 °C (174-181 °F)

Fully open 93-96 °C (199-205 °F)
WATER PUMP
Type Centrifugal
DRIVE BELT
Belt tension Maintained by tensioner
COOLING CAPACITIES
See CS Operators Manual
COOLANT FLOW
Coolant flow at rated engine speed 340.6 L/min (90 US gpm)
COOLING FLUID
See CS Operators Manual
12126 1 02/07/2004
B.50.A / 3
ENGINE COOLANT SYSTEM - Static description (B.50.A - C.30.A.20)

CS540, CS640, CS520, CS660
The function of the water pump mounted at the front of the engine (arrow) is to maintain a continuous flow of
water around the cooling system. This is essential to ensure correct engine temperature and performance during
vehicle operation.
The water pump, is driven by a "Poly V-belt", from the crankshaft pulley when the engine is running. The drive belt
tension is maintained by a spring-loaded belt tensioner bolted to the front cover.
ZDF0807D 1
The thermostats are located in the top of the housing above the water pump body and control the flow of the
water as required by temperature changes.
NOTE: A faulty thermostat may cause the engine to operate at a too hot or too cold operating temperature. If not
replaced, this could result in damage to the engine or impaired engine performance.
IMPORTANT: Do not operate an engine without a thermostat.
DSD1757A 2
The cooling system is of the recirculating bypass type with full-length water jackets for each cylinder. The coolant is
drawn from the bottom of the radiator by the water pump which passes the coolant to the cylinder block. The coolant
then flows through cored passages to cool the cylinder walls.
NOTE: These engines are also fitted with an oil cooler in the circuit. Coolant from the radiator passes through the oil
cooler before entering the cylinder block.
10_10-2_03 3
12126 1 02/07/2004
B.50.A / 4
Passages in the cylinder head gasket allow coolant to flow from the cylinder block into the cylinder head. Cored
passages also direct the coolant to the fuel injector nozzle locations before entering the thermostat housing.
Dependent upon water temperature, water either reenters the water pump or is circulated through the radiator
for cooling.
When the thermostat is closed, a recirculating bypass allows the coolant to recirculate from the head to the block,
to effect faster warm-up.
10_10-2_04 4
Once the engine has reached its normal operating temperature, the thermostat will open and allow water to be
drawn through the radiator by the pump action. Cooled water then returns to the engine system.
Cooling occurs as the coolant passes down through the radiator cores which are exposed to the air cooling system.
Air is pulled through a rotary screen and the radiator by means of a powerful engine-mounted fan. Air is also
pulled through the ducting (1) mounted under the radiator and the rotary screen to lift large chaff particles off
the surface of the rotary screen. A brush (if installed), mounted inside the rotary screen, dislodges the particles
to prevent plugging of the rotary screen.
ZDF0823A 5
12126 1 02/07/2004
B.50.A / 5
Thermostat - Remove (B.50.A.18 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Drain the coolant system below the level of the

thermostat housing.
DSD1757A 1
2. Remove the thermostat housing and withdraw the

two thermostats.
12126 1 02/07/2004
B.50.A / 6
Thermostat - Check (B.50.A.18 - F.40.A.11)

CS540, CS640, CS520, CS660
1. Place both thermostats in a container of water and

raise the temperature to 100 ° C (212 ° F). If either
thermostat fails to open when hot, or close properly
when cooled, it must be replaced.
RI-1-107 1
12126 1 02/07/2004
B.50.A / 7
Thermostat - Install (B.50.A.18 - F.10.A.15)

CS540, CS640, CS520, CS660
Installation of the thermostats is the reverse of the removal procedure, but observe the following:
1. Coat the new gasket with sealer 82995774 and

position on the thermostat housing, prior to installing
the thermostat.
DSD1757A 1
2. Coat the edge of the thermostat with grease and

install, with the heat element located in the cylinder
head.
3. Refit the thermostat housing and torque the bolts
between 20 - 28 Nm (15 - 21 lb ft).
12126 1 02/07/2004
B.50.A / 8
Water pump - Remove (B.50.A.20 - F.10.A.10)

CS540, CS640, CS520, CS660
To overhaul the water pump components, i.e, bearing, impeller or shaft seal, carry out the following:
1. Drain the cooling system.
BSD1855A 1
2. Remove the bolts securing the fan shroud and move

the shroud to gain access to the engine.
3. Remove the fan belt from the vehicle.
4. Disconnect tube (1) from rear of cylinder head at
the water pump (flexible coupling).
5. Withdraw the four bolts (2) which pass through
the water pump and into the block, and slide the
complete pump forward and away from the block.
Note the sealing O-ring which may come off with
the pump or be left on the block. Also observe
the transfer tube between the water pump and
thermostat housing. Ensure the tube and O-rings
do not become dislodged and lost.
12126 1 02/07/2004
B.50.A / 9
Water pump - Disassemble (B.50.A.20 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Remove the securing bolts from the adaptor cover

on the rear of the pump body. Carefully ease out the
adaptor. Remove and discard the O- ring.
10_10-2_11 1
2. With the adapter cover removed, pry the back plate

off.
10_10-2_12 2
3. Place the pump body between the two supports (3)

and by gently pressing on the shaft, push the shaft
and pulley (4) away from the impeller (2) and out of
the pump body (1).
10_10-2_13 3
12126 1 02/07/2004
B.50.A / 10
4. With the impeller/shaft assembly removed from the

pump, place the pulley (1) on supports (2) and press
out the shaft assembly (3) from the pulley.
10_10-2_14 4
5. The seal assembly attached to the bearing shaft

is not removable or serviceable. During the
manufacturing process, the seal is pressed onto the
shaft and destroyed on removal. This is to meet
preload conditions and maintain an effective wear
seal.
12126 1 02/07/2004
B.50.A / 11
Water pump - Check (B.50.A.20 - F.40.A.11)

CS540, CS640, CS520, CS660
1. Check the bearing shaft and seal assembly for

signs of wear or leaks and if evident, the assembly
must be replaced with new parts.
2. The impeller should be checked for worn or
damaged vanes and must be replaced if not to an
acceptable standard.
3. Clean and check the pump body for signs of cracks,
erosion or leaks. If any of these faults are in
evidence and likely to cause pump failure at a later
date, the pump body must be repaired or replaced
with a new one.
12126 1 02/07/2004
B.50.A / 12
Water pump - Assemble (B.50.A.20 - F.10.A.20)

CS540, CS640, CS520, CS660
1. To install the bearing (1) into the pump body (3)

place the body rear face down onto a flat surface.
Install the bearing with the longer stepped end of
the shaft in the body and using a sleeve (4) that
contacts the bearing outer race only. Use a press
(5) to press the bearing into the body. Once installed
in the body, the bearing case end face must be flush
with the pump front face to within 0.00 mm - 0.076
mm (0.000 in - 0.006 in), (6).
NOTE: Use Loctite 262, around the pulley bore chamfer
and press the pulley onto the shaft.
R1-2-110 1
2. With the water pump (4) placed front face down and
the shaft (6) supported with suitable blocks (5) place
the seal assembly (3) on the end of the shaft with
its smallest diameter uppermost. To insert the seal
assembly, place tool (2) over the seal and use a
press (1) to press until the lip on the seal body seats
on the pump body.
10_10-2_16 2
3. With the seal installed correctly, the seal working

height should be maintained at 10.9 mm - 11.7 mm
(0.430 in - 0.460 in),(1).
10_10-2_17 3
12126 1 02/07/2004
B.50.A / 13
4. With the water pump rear (1) face up, and the shaft
supported, place the impeller (2) over the shaft (3)
and press the impeller into the water pump body.
Installed correctly the face of the impeller fins to the
operating face of the water pump should be 0.25
mm - 0.88 mm (0.010 in - 0.035 in).
To achieve this, check the dimension from the rear
face of the impeller to the rear face of the pump.
The dimension should be maintained at 28.07 mm -
28.58 mm (1.105 in - 1.125 in), (5).
With the pump rear face down and the shaft
supported, press the pulley onto the shaft ensuring
the pulley front face to the rear face of the pump
dimension is 157.10 mm - 157.86 mm (6.185 in -
4
6.215 in). 10_10-2_18
5. Ensure a new O-ring is fitted and place the water

pump back plate in position. Make sure the water
pump pulley/impeller assembly rotates freely by
hand prior to reassembly. If not, disassemble and
recheck the dimensions.
10_10-2_20 5
12126 1 02/07/2004
B.50.A / 14
10_10-2_19 6
Water pump dimensions
1 Seat and seal assembly 2 Impeller

3 Bearing 4 Pulley
5 Pulley shaft mating face
12126 1 02/07/2004
B.50.A / 15
Water pump - Install (B.50.A.20 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Installation of water pump to the engine is the

reverse of remove. Refer to Water pump - Remove
(B.50.A.20 - F.10.A.10).
2. Ensure the drive belt tensioner pulley rotates freely
and the swinging arm of the tensioner returns to rest
freely. Gently lever the arm up, to enable the drive
belt to be seated in the grooves on the pulleys.
3. After installation, refill the cooling system as
previously described and run the engine checking
for leaks.
12126 1 02/07/2004
B.50.A / 16
Rotary screen Motor - Open circuit (B.50.A.58.01 - G.30.B.50)

CS540, CS640, CS520, CS660
E601 - ROTARY DUST SCREEN BRUSHES ACTUATOR (M14) OUTPUT OPEN OR SHORT CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty reel brushes slow relay
4. Faulty reel brushes fast relay
5. Faulty rotary dust screen brushes actuator
Solution:
1. Check the rotary dust screen brushes actuator connector X102, CCM connector X142, and the in-line harness
connectors X10, X138, and X194.

2. Check for a short to +Ve.
A. Disconnect relay K53 and K53.1. Turn the key start ON. Measure the voltage between connector:
K53 pin 5, circuit (608) (GR) and ground
K53.1 pin 5, circuit (052) (WT) and ground
If a voltage is indicated, repair or replace the harness as required.
B. If a voltage is not indicated, continue to step 3.

3. Check for short to ground.
A. Turn the key start OFF. Check between connector:

K53 pin 5, circuit (608) (GR) and ground
K53.1 pin 5, circuit (052) (WT) and ground
If a short to ground is indicated, repair or replace the harness as required.
B. If a short to ground is not indicated, continue to step 4.


K53 pin 5, circuit (608) (GR) and connector X102 pin 2, circuit (608) (GR)
K53.1 pin 5, circuit (052) (WT) and connector X102 pin 3, circuit (052) (WT)
B. If the harness is okay, remove and replace the rotary dust screen brushes actuator. If the fault is still
present, download the correct level of software. If the fault re-occurs, remove and replace the CCM.
12126 1 02/07/2004
B.50.A / 17

(A.30.A - C.20.E.10)
CS540 1260 > 1324
CS640 1260 > 1324

A8. CCM - reel 2730
X19. Header 2820
Line: 2720 - 2880
12126 1 02/07/2004
B.50.A / 18
vfil04cs0018h0a 1
12126 1 02/07/2004
B.50.A / 19

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

A8. CCM - reel 2730
X19. Header 2820
Line: 2720 - 2880
12126 1 02/07/2004
B.50.A / 20
vfil04cs0019h0a 2
12126 1 02/07/2004
B.50.A / 21
Index
ENGINE COOLANT SYSTEM - General specification (B.50.A - D.40.A.10) 3

CS540, CS640, CS520, CS660
ENGINE COOLANT SYSTEM - Static description (B.50.A - C.30.A.20) 4
CS540, CS640, CS520, CS660
ENGINE COOLANT SYSTEM - Torque (B.50.A - D.20.A.10) 3
CS540, CS640, CS520, CS660
Rotary screen Motor - Open circuit (B.50.A.58.01 - G.30.B.50) 17
CS540, CS640, CS520, CS660
Thermostat - Check (B.50.A.18 - F.40.A.11) 7
CS540, CS640, CS520, CS660
Thermostat - Install (B.50.A.18 - F.10.A.15) 8
CS540, CS640, CS520, CS660
Thermostat - Remove (B.50.A.18 - F.10.A.10) 6
CS540, CS640, CS520, CS660
Water pump - Assemble (B.50.A.20 - F.10.A.20) 13
CS540, CS640, CS520, CS660
Water pump - Check (B.50.A.20 - F.40.A.11) 12
CS540, CS640, CS520, CS660
Water pump - Disassemble (B.50.A.20 - F.10.A.25) 10
CS540, CS640, CS520, CS660
Water pump - Install (B.50.A.20 - F.10.A.15) 16
CS540, CS640, CS520, CS660
Water pump - Remove (B.50.A.20 - F.10.A.10) 9
CS540, CS640, CS520, CS660
12126 1 02/07/2004
B.50.A / 22
LUBRICATION SYSTEM - 60.A
CS540
CS640
CS520
CS660
12127 1 02/07/2004
B.60.A / 1
Contents
TECHNICAL DATA
LUBRICATION SYSTEM - General specification (B.60.A - D.40.A.10) 3

CS540, CS640, CS520, CS660
FUNCTIONAL DATA
LUBRICATION SYSTEM - Static description (B.60.A - C.30.A.20) 4

CS540, CS640, CS520, CS660
SERVICE
Oil pump
Oil pump - Remove (B.60.A.20 - F.10.A.10) 7
CS540, CS640, CS520, CS660
Oil pump - Overhaul (B.60.A.20 - F.10.A.40) 8
CS540, CS640, CS520, CS660
Oil pump - Install (B.60.A.20 - F.10.A.15) 9
CS540, CS640, CS520, CS660
Oil pan
Oil pan - Remove (B.60.A.23 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Oil pan - Install (B.60.A.23 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Oil pressure regulator

Oil pressure regulator - Remove (B.60.A.25 - F.10.A.10) 12
CS540, CS640, CS520, CS660
Oil pressure regulator - Install (B.60.A.25 - F.10.A.15) 13
CS540, CS640, CS520, CS660
12127 1 02/07/2004
B.60.A / 2
POWER PRODUCTION - LUBRICATION SYSTEM
LUBRICATION SYSTEM - General specification (B.60.A - D.40.A.10)

CS540, CS640, CS520, CS660
OIL PUMP
Flow rate 91 l/min. (20 lmp Gpm) at 2100 Engine RPM and 1.38 bar (20 psi)
Rotor clearance 0.025-0.15 mm (0.001-0.006 in)
Rotor to pump housing clearance 0.15-0.28 mm (0.006-0.011 in)
Rotor end play 0.025-0.089 mm (0.001-0.0035 in)
Pump gear to camshaft gear backlash 0.40-0.56 mm (0.016-0.022 in)
OIL PRESSURE
Minimum at low idle speed 0.83 bar (12 psi) at normal operating temperature
Minimum at engine rated speed 2.41 bar (35 psi) at normal operating temperature
OIL FILTER SUPPORT
Relief valve, Operating pressure 3.8-4.1 bar (55-60 psi)

Flow rate 68.1-75.7 l/min. (15-16.6 imp gal/min,18-20 US gal/min)
ENGINE OILS AND CHANGE PERIODS

Refer to the CS Operators manual
ENGINE OIL CAPACITIES
Model Imp Pints U.S. Gallons Liters

6 CYL 48.6 6.08 23.0
GREASE and SEALANTS
Code Number Name

A NLG1 Grade 2 Grease
B ESF-M1C43-A Grease-silicone light consistency
C 82995768 Sealer-anaerobic low strength (Loctite™ 565)
D&J 82995776 Sealer-silicone
E&F 82995774 Sealer-polyester urethane
G 82995773 Sealer-anaerobic (Loctite™ 565)
K 82995772 Thread and stud lock(Loctite™ 565)
L 82995771 Flexible gasket sealant
12127 1 02/07/2004
B.60.A / 3
LUBRICATION SYSTEM - Static description (B.60.A - C.30.A.20)

CS540, CS640, CS520, CS660
10_2-23_10 1
Engine lubrication system
Lubrication of the engine, Fig. 1 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 2
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.
10_2-23_12 3
12127 1 02/07/2004
B.60.A / 4
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 pressurization of the system.
396-E-18 4
The spin on type oil filter (1) is mounted at the rear of the engine.
ZDA6077A 5
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 6
12127 1 02/07/2004
B.60.A / 5
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_2 7
1Timing gears are lubricated by splashed oil from the cam follower chamber, and the pressure lubricated camshaft
drive gear bushing.
P396-E-36 8
The turbocharger is supplied with oil from the oil filter support housing (1) mounted on the left hand side of the engine.
SMC1008 9
The fuel injection pump is pressure lubricated from a port on the right hand side of the engine block.
10_2-23_19 10
12127 1 02/07/2004
B.60.A / 6
Oil pump - Remove (B.60.A.20 - F.10.A.10)

CS540, CS640, CS520, CS660
NOTE: The oil pump can only be removed with the engine split from the transmission and the flywheel, back plate,
engine oil pan, and oil pump tube removed.
1. Prior to pump removal check pump gear to camshaft
gear backlash does not exceed, 0.40-0.56 mm
(0.016-0.022 in).
TA6010057 1
2. Loosen and remove the camshaft gear, to expose

the oil pump, detach the 3 pump mounting bolts,
and withdraw the pump from the block.
TA6010058_12 2
12127 1 02/07/2004
B.60.A / 7
Oil pump - Overhaul (B.60.A.20 - F.10.A.40)

CS540, CS640, CS520, CS660
1. Loosen and remove the pump face plate to body

bolts (4) off. Disassemble the pump and discard
the O-rings.
TA6010059 1
2. Inspection and repair :

Wash all parts in a suitable solvent and inspect
inside of pump plate, and body, for excessive wear
or damage. If visually okay check in the following
manner.
Invert pump plate/rotor assembly, and place outer
rotor over inner rotor. Placing a ruler across top
of both, slide a feeler gauge, between ruler and
inner rotor and measure clearance which must be
0.025-0.089 mm (0.001-0.0035 in), Fig. 2.
TA6010060 2
3. Place outer rotor in pump body and check

clearance, by inserting a feeler gauge between the
rotor and body. Check clearance does not exceed
a maximum of 0.55 mm (0.022 in). If exceeded a
new pump is required.
NOTE: If not to specification replace the oil pump, as
reduced pump pressure through wear could result in
reduced engine life.
TA6010061 3
12127 1 02/07/2004
B.60.A / 8
Oil pump - Install (B.60.A.20 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Clean and coat parts in new engine oil. Place outer

rotor in pump body, and ensure free rotation. Insert
inner rotor, and pump plate assembly, into the body
and ensure that shaft is fully seated into bushing.
Assemble the front plate to the body and torque the
retaining bolts to, 23.0-28.4 Nm (17-21 lb ft).
NOTE: After tightening ensure the drive gear rotates
freely by hand, at least 5 revolutions, if not disassemble
and repeat the exercise.
TA6010059_13 1
2. Fit a new O-ring (1), Fig. 1, to the output tube,

lubricate and insert the pump into the block
tightening the bolts to 23.0-28.4 Nm (17-21 lb ft.).
Fit a new O-ring (2), Fig. 1, into the suction port.
Lubricate and insert tube/screen assembly (2) into
pump (1) through bottom of engine. Fitting a new
gasket (4) and torque the attaching bolts (3) Fig. 3,
to, 27-34 Nm (20-25 lb ft).
TA6010058_14 2
3. Refit gears as previously described along with the

rear plate, and flywheel.
NOTE: Plug (5) Fig. 3, is factory installed to facilitate
machining, and should not be removed during the life of
the engine.
TA6010062 3
12127 1 02/07/2004
B.60.A / 9
Oil pan - Remove (B.60.A.23 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the engine.

2. Drain engine oil through oil pan drain plug and
remove the dipstick.
3. Remove oil pan bolts and lower pan to the ground.
10_30-50_39_31 1
12127 1 02/07/2004
B.60.A / 10
Oil pan - Install (B.60.A.23 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Clean gasket material from sump face, clean sump

in a suitable solvent, inspect sump for cracks
damaged threads or damaged sump face.
10_30-50_39_31 1
2. Installation is the reverse of removal but with the

following requirements.
Ensure block face is clean and free of gasket
material.
NOTE: Before installing the oil pan ensure that the rear oil
seal carrier (2) is correctly aligned with the block (1) i.e.,
less than 0.15 mm protrusion or 0.22 mm recessed.
10_30-50_40_33 2
3. Apply gasket sealant 82995770 (NA-L51831DS,

Loctite™ 518) to the areas shown and install a new
gasket to the oil pan.
BSD1845A 3
4. Position the oil pan and install a bolt finger tight at

each corner. Install remaining bolts, and torque to
44 Nm (33 lb ft).
12127 1 02/07/2004
B.60.A / 11
Oil pressure regulator - Remove (B.60.A.25 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove plug (3) spring (2) and valve (1) To ensure

correct operation of the pressure relief valve, check
spring length,
Free length = 52.8 mm (2.08 in).
Compressed length = 37.0 mm (1.46 in) using a
weight of 15.6 kg (34.3 lb).
396-E-18_15 1
2. Clean assembly in a suitable solvent and ensure

all ports are free of dirt.
3. Check the parts for damage, wear, and replace
as necessary. Failure to do so could result in
premature wear to the engine, due to oil by-passing
the filter and returning back to the system.
12127 1 02/07/2004
B.60.A / 12
Oil pressure regulator - Install (B.60.A.25 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Lubricate the pressure relief valve (1) and spring (2),

and insert into housing, ensuring free movement.
Fit a new O-ring to plug (3) and torque to 55 Nm
(42 lb ft.).
396-E-18_15 1
12127 1 02/07/2004
B.60.A / 13
Index
LUBRICATION SYSTEM - General specification (B.60.A - D.40.A.10) 3

CS540, CS640, CS520, CS660
LUBRICATION SYSTEM - Static description (B.60.A - C.30.A.20) 4
CS540, CS640, CS520, CS660
Oil pan - Install (B.60.A.23 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Oil pan - Remove (B.60.A.23 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Oil pressure regulator - Install (B.60.A.25 - F.10.A.15) 13
CS540, CS640, CS520, CS660
Oil pressure regulator - Remove (B.60.A.25 - F.10.A.10) 12
CS540, CS640, CS520, CS660
Oil pump - Install (B.60.A.20 - F.10.A.15) 9
CS540, CS640, CS520, CS660
Oil pump - Overhaul (B.60.A.20 - F.10.A.40) 8
CS540, CS640, CS520, CS660
Oil pump - Remove (B.60.A.20 - F.10.A.10) 7
CS540, CS640, CS520, CS660
12127 1 02/07/2004
B.60.A / 14
STARTING SYSTEM - 80.A
CS540
CS640
CS520
CS660
12128 1 02/07/2004
B.80.A / 1
Contents
FUNCTIONAL DATA
STARTING SYSTEM - Logical diagram (B.80.A - C.20.B.72) 3

CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
DIAGNOSTIC
STARTING SYSTEM - Problem solving (B.80.A - G.40.A.30) 7

CS540, CS640, CS520, CS660
Engine starter
Engine starter - Testing (B.80.A.82 - G.40.A.20) 8
CS540, CS640, CS520, CS660
Start control
Start control Start relay - Testing (B.80.A.90.80 - G.40.A.20) 8
CS540, CS640, CS520, CS660
Start control - Testing (B.80.A.90 - G.40.A.20) 9
CS540, CS640, CS520, CS660
Start control Start switch - Testing (B.80.A.90.82 - G.40.A.20) 10
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Cold start control

Cold start control - Testing (B.80.A.91 - G.40.A.20) 11
CS540, CS640, CS520, CS660
12128 1 02/07/2004
B.80.A / 2
POWER PRODUCTION - STARTING SYSTEM
STARTING SYSTEM - Logical diagram (B.80.A - C.20.B.72)

CS540, CS640, CS520, CS660
07_1_8_04 1
STARTING SYSTEM
12128 1 02/07/2004
B.80.A / 3
STARTING FIGURE KEY

G3 ALTERNATOR
H1 ALTERNATOR WARNING LIGHT
H12 ENGINE OIL PRESSURE WARNING LIGHT
H16 HYDROSTATIC OIL PRESSURE AND OIL TEMPERATURE WARNING LIGHT
K1 STARTER RELAY
M1 STARTER MOTOR
Initial conditions:
The battery switch (S1) must be switched on, the start protection switch (S2) in the closed position and the
multifunction handle placed in neutral.
When the initial conditions are met and the keystart is in position 1, the engine protection circuit is activated
illuminating the warning lights (H1, H12 and H16), and the engine protection relay (K3). The warning buzzer sounds
and the engine stop solenoid (Y3) hold coil is deactivated.
When the engine protection override switch (S9) is activated.
When the engine protection switch (S9) is activated (reset), the engine protection relay (K3) is deactivated supplying
power to activate the engine stop solenoid (Y3) hold coil. When the key start is placed into position 2 (crank), the
starter relay (K1) is activated, this supplies power to the engine stop solenoid (Y3) pull coil and the starter motor
(M1). The engine now starts and the alternator (G3) is now activated.
As the engine starts, the engine protection sensors (H1, H12 and H16) are deactivated. The engine protection
relay (K3) remains deactivated, supplying power to the engine stop solenoid (Y3) hold coil. On releasing the key
start, the starter relay (K1) is deactivated which cuts power to the starter motor (M1) and the engine stop solenoid
(Y3) pull coil, deactivating them.
When the engine protection override switch (S9) is not activated.
With the key start is in position 2 (crank), the starter relay (K1) is activated, supplying power to the engine stop
solenoid (Y3) pull coil (the Y3 hold coil is still deactivated) and the starter motor (M1), activating them. The engine
now starts and the alternator (G3) is now activated.
As the engine starts the engine protection sensors (H1, H12 and H16) are deactivated. With the engine running the
engine protection relay (K3) is deactivated supplying power to the engine stop solenoid (Y3) hold coil. On releasing
the key start the starter relay (K1) is deactivated, which cuts power to the starter motor (M1) and the engine stop
solenoid (Y3) pull coil, deactivating them.
12128 1 02/07/2004
B.80.A / 4
STARTING SYSTEM - Logical diagram (B.80.A - C.20.B.72)

CS540, CS640, CS520, CS660
07_17_20_02 1
ENGINE KILL STOP
12128 1 02/07/2004
B.80.A / 5
ENGINE KILL STOP FIGURE KEY

Initial conditions:
The key start (S3) must be switched on, the start protection switch (S2) in the on (closed) position and the engine
running under normal operating conditions (warning detection signal high).
When the initial conditions are met and the engine protection switch (S9) (kill stall) is activated, the kill stall signal is
detected (signal low) and the engine protection relay (K3) is activated which cuts the power supply to the engine
stop solenoid (Y3) hold coil, deactivating it and stopping the engine.
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B.80.A / 6
STARTING SYSTEM - Problem solving (B.80.A - G.40.A.30)

CS540, CS640, CS520, CS660
OPERATION
When the key start is placed in the "START" position and the starter protection switch is in the "CLOSED" position,
current flows through the coil side of the starter relay and then to ground. This closes the switch side of the starter
relay and allows current flow to energize the solenoid of the starter and the starter motor will operate.
TROUBLESHOOTING
B. Check fuses #1, #13 and #26.
C. The transmission is in neutral or park.
D. Battery switch closed.
CAUTION
CAUTION

Engine does not crank Fuse #1. A - Key start switch power supply test.Start
when key start switch is control - Testing (B.80.A.90 - G.40.A.20)
turned to start
Key start switch (S3). B - Key start switch (S3) test.Start control
Start switch - Testing (B.80.A.90.82 -
G.40.A.20)
Engine protection (Neutral) switch (S2). C - Engine protection (Neutral) switch
(S2) test.Cold start control - Testing
(B.80.A.91 - G.40.A.20)
Starter relay circuit(s). D - Start relay (K1) circuit test.Start control
Start Relay (K1). Start relay - Testing (B.80.A.90.80 -
G.40.A.20)
Starter relay circuit(s). If test D is okay, install a new starter relay.
Start Relay (K1).
Starter motor circuit. E - Starter motor circuit test.Engine
Starter motor (M1). starter - Testing (B.80.A.82 - G.40.A.20)
Starter motor circuit. If test E is okay, install a new starter motor.
Starter Motor (M1).
The relay clicks but the Starter relay (K1). D - Starter relay (K1) circuit test.Start
engine does not crank control Start relay - Testing
(B.80.A.90.80 - G.40.A.20)
Starter relay (K1). If test D is okay, install a new starter relay.
Start motor (M1). E - Starter motor circuit test.Engine
starter - Testing (B.80.A.82 - G.40.A.20)
Start Motor (M1). If test E is okay, install a new starter motor.
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B.80.A / 7

Engine cranks slowly Starter Motor F - Starter Motor Circuit Test. Start control
Start switch - Testing (B.80.A.90.82 -
G.40.A.20)
Engine mechanical problem Refer to Engine Section in the Repair
Manual.
Starter motor continues Key start Switch. B - Ignition Switch Test, and confirm
to operate when key start that switch opens when key start is
switch is released from released.Start control Start switch -
START to ACC position Testing (B.80.A.90.82 - G.40.A.20)
Starter Relay. D - Start Relay Test, and confirm that relay
opens when key is released.Start control
Start relay - Testing (B.80.A.90.80-
G.40.A.20)
Starter Motor. If Tests B and D are okay, install a new
Starter Motor.
Engine starter - Testing (B.80.A.82 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Check for 12 volts at Starter Motor 12 volts. Open circuit between Starter B+
B+ terminal (30). If good reading, starter motor circuit terminal (30) and Battery positive
is okay. terminal, circuit 001 (RD).
Caution: When performing
continuity test on this circuit, ensure
that the cable is disconnected from
the battery positive terminal.
Failure to do so can result in
damage to the test meter.
Start control Start relay - Testing (B.80.A.90.80 - G.40.A.20)

CS540, CS640, CS520, CS660
12128 1 02/07/2004
B.80.A / 8
CAUTION
WARNING

1 Remove the starter relay K1. 12 volts. Open circuit between starter relay
Place the key start switch in If good reading, continue with next connector terminal (pin 86) and
"START" position. step. engine protection (Neutral) switch
Check for 12 volts at start relay K1 (S2), circuit 013 (WT).
terminal (pin 86).
2 Turn the key start “OFF". 12 volts. Open circuit between start relay
Check for 12 volts at start relay K1 If good reading, continue with next terminal (pin 30) and starter B+
terminal (pin 30). step. terminal, circuit 011 (RD).
3 Check for a ground at start relay K1 Less than 1 ohm. Open circuit between start relay
terminal (pin 85). If good reading, go to next test point. terminal (pin 85) and ground, circuit
040 (ZW).
4 Measure resistance between starter Less than 1 ohm. Open circuit between starter relay
relay terminal (pin 87) and starter If good reading, start relay circuits terminal (pin 87) and starter motor
motor terminal (pin 50), circuit 009 are okay. terminal (pin 50), circuit 009 (WT).
(WT).
Start control - Testing (B.80.A.90 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Check for 12 volts at key start 12 volts. Open between fuse #1 and key start
switch connector (pin 4), (RD). If good reading, continue with next switch connector (pin 4), circuit 015
step. (RD).
2 Place the key start switch in "ACC" 12 volts. Key start switch.
position. If good reading, continue with next
Check for 12 volts at key start step.
switch connector (pin 1), (WT).
3 Place the key start switch in 12 volts. Key start switch.
"START" position. If good reading, key start switch is
Check for 12 volts at key start okay.
switch connector (pin 2), (WT).
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B.80.A / 9
Start control Start switch - Testing (B.80.A.90.82 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 While holding key start switch in Less than 0.5 volts. High resistance in circuit 001 (RD).
the "START" position, measure the If good reading, continue with next Clean and tighten battery positive
voltage between starter motor B+ step. terminal connections.
terminal (30) and battery positive
terminal.
2 While holding key start switch in Less than 0.5 volts. High resistance in circuit 002 (ZW).
the "START" position, measure If good reading, starter motor Clean and tighten battery and
between starter motor housing and circuit(s) are okay. engine ground cable connections.
battery negative terminal.
Start control Start switch - Testing (B.80.A.90.82 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the key start switch Less than 1 ohm. Key start switch.
connector S3. If good reading, continue with next
While holding key start switch in step.
the "START" position, measure
between (pins 2 and 4).
2 While holding key start switch in Less than 1 ohm. Key start switch.
the "START" position, measure If good reading, continue with next
between (pins 1 and 4). step.
3 Place the key start switch in "ACC" Less than 1 ohm. Key start switch.
position, measure between (pins 1 If good reading, continue with next
and 4). step.
4 Place the key start switch in the Open circuit. Key start switch.
"OFF" position, measure between If good reading, key start switch is
(pin 4 and pin 1) (pin 4 and pin 2). okay.
12128 1 02/07/2004
B.80.A / 10
Cold start control - Testing (B.80.A.91 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the in-line harness Less than 1 ohm. Open in circuit 014 (WT).
connector X161. If good reading, continue with next Engine protection (Neutral) switch.
Place the multifunction handle in the step.
"Neutral" position.
Measure between connector X161
(pin B) and (pin N).
2 Place the multifunction handle out Open circuit. Engine protection (Neutral) switch.
of the "Neutral" position. If good reading, engine protection
Measure between connector X161 (Neutral) switch is okay.
(pin B) and (pin N).
12128 1 02/07/2004
B.80.A / 11
Index
Cold start control - Testing (B.80.A.91 - G.40.A.20) 11

CS540, CS640, CS520, CS660
Engine starter - Testing (B.80.A.82 - G.40.A.20) 8
CS540, CS640, CS520, CS660
Start control - Testing (B.80.A.90 - G.40.A.20) 9
CS540, CS640, CS520, CS660
Start control Start relay - Testing (B.80.A.90.80 - G.40.A.20) 8
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
STARTING SYSTEM - Problem solving (B.80.A - G.40.A.30) 7
CS540, CS640, CS520, CS660
12128 1 02/07/2004
B.80.A / 12
12128 1 02/07/2004
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PRINTED IN BELGIUM
12122 1 02/07/2004
REPAIR MANUAL
POWER TRAIN
CS540
CS640
CS520
CS660
12129 1 02/07/2004
C
Contents
POWER TRAIN - C
TRANSMISSION Mechanical C.20.B

CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic C.20.F

CS540, CS640, CS520, CS660
PROCESS DRIVE Primary process drive C.50.B

CS540, CS640, CS520, CS660
12129 1 02/07/2004
C
POWER TRAIN - C
TRANSMISSION Mechanical - 20.B
CS540
CS640
CS520
CS660
12130 1 02/07/2004
C.20.B / 1
Contents
POWER TRAIN - C
TECHNICAL DATA
TRANSMISSION Mechanical - Torque (C.20.B - D.20.A.10) 5

CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Special tools (C.20.B - D.20.A.40) 5
CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - General specification (C.20.B - D.40.A.10) 5
CS520
CS540, CS640, CS520, CS660
CS660
FUNCTIONAL DATA
TRANSMISSION Mechanical - Mechanical schema (C.20.B - C.20.A.10) 7

CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Sectional view (C.20.B - C.10.A.30) 8
CS540, CS640, CS520, CS660
Shaft
Shaft Input shaft - Overview (C.20.B.43.01 - C.10.A.10) 9
CS540, CS640, CS520, CS660
Shaft Input shaft - Exploded view (C.20.B.43.01 - C.10.A.20) 10
CS540, CS640, CS520, CS660
Shaft Input shaft - Sectional view (C.20.B.43.01 - C.10.A.30) 11
CS540, CS640, CS520, CS660
Shaft Drive shaft - Overview (C.20.B.43.02 - C.10.A.10) 12
CS540, CS640, CS520, CS660
Shaft Drive shaft - Exploded view (C.20.B.43.02 - C.10.A.20) 13
CS540, CS640, CS520, CS660
Shaft Drive shaft - Sectional view (C.20.B.43.02 - C.10.A.30) 15
CS540, CS640, CS520, CS660
Shaft Differential shaft - Exploded view (C.20.B.43.03 - C.10.A.20) 16
CS540, CS640, CS520, CS660
Differential
Differential - Sectional view (C.20.B.50 - C.10.A.30) 18
CS540, CS640, CS520, CS660
Differential - Exploded view (C.20.B.50 - C.10.A.20) 19
CS540, CS640, CS520, CS660
Shifting disc system

Shifting disc system - Exploded view (C.20.B.60 - C.10.A.20) 20
CS540, CS640, CS520, CS660
Cover
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C.20.B / 2
Cover - Exploded view (C.20.B.75 - C.10.A.20) 22
CS540, CS640, CS520, CS660
SERVICE
TRANSMISSION Mechanical - Remove (C.20.B - F.10.A.10) 24

CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Disassemble (C.20.B - F.10.A.25) 27
CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Assemble (C.20.B - F.10.A.20) 28
CS540, CS640, CS520, CS660
Shaft
Shaft Input shaft - Remove (C.20.B.43.01 - F.10.A.10) 29
CS540, CS640, CS520, CS660
Shaft Input shaft - Disassemble (C.20.B.43.01 - F.10.A.25) 32
CS540, CS640, CS520, CS660
Shaft Input shaft - Assemble (C.20.B.43.01 - F.10.A.20) 34
CS540, CS640, CS520, CS660
Shaft Input shaft - Install (C.20.B.43.01 - F.10.A.15) 36
CS540, CS640, CS520, CS660
Shaft Drive shaft - Remove (C.20.B.43.02 - F.10.A.10) 40
CS540, CS640, CS520, CS660
Shaft Drive shaft - Disassemble (C.20.B.43.02 - F.10.A.25) 42
CS540, CS640, CS520, CS660
Shaft Drive shaft - Assemble (C.20.B.43.02 - F.10.A.20) 44
CS540, CS640, CS520, CS660
Shaft Drive shaft - Install (C.20.B.43.02 - F.10.A.15) 46
CS540, CS640, CS520, CS660
Shaft Differential shaft - Remove (C.20.B.43.03 - F.10.A.10) 48
CS540, CS640, CS520, CS660
Shaft Differential shaft - Disassemble (C.20.B.43.03 - F.10.A.25) 51
CS540, CS640, CS520, CS660
Shaft Differential shaft - Assemble (C.20.B.43.03 - F.10.A.20) 52
CS540, CS640, CS520, CS660
Differential
Differential - Disassemble (C.20.B.50 - F.10.A.25) 54
CS540, CS640, CS520, CS660
Differential - Assemble (C.20.B.50 - F.10.A.20) 56
CS540, CS640, CS520, CS660
Differential - Install (C.20.B.50 - F.10.A.15) 58
CS540, CS640, CS520, CS660
Differential lock command

Differential lock command - Adjust (C.20.B.51 - F.45.A.01) 60
CS540, CS640, CS520, CS660
Shifting disc system

Shifting disc system Selector shaft - Remove (C.20.B.60.40 - F.10.A.10) 62
CS540, CS640, CS520, CS660
Shifting disc system Selector shaft - Install (C.20.B.60.40 - F.10.A.15) 63
CS540, CS640, CS520, CS660
Shifting disc system Disc - Remove (C.20.B.60.41 - F.10.A.10) 64
CS540, CS640, CS520, CS660
Shifting disc system Disc - Install (C.20.B.60.41 - F.10.A.15) 65
CS540, CS640, CS520, CS660
Shifting disc system Bar - Adjust (C.20.B.60.42 - F.45.A.01) 67
CS540, CS640, CS520, CS660
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C.20.B / 3
Cover
Cover - Remove (C.20.B.75 - F.10.A.10) 69
CS540, CS640, CS520, CS660
Cover - Disassemble (C.20.B.75 - F.10.A.25) 70
CS540, CS640, CS520, CS660
Cover - Assemble (C.20.B.75 - F.10.A.20) 71
CS540, CS640, CS520, CS660
Cover - Install (C.20.B.75 - F.10.A.15) 72
CS540, CS640, CS520, CS660
DIAGNOSTIC
Sensing system
Sensing system Ground speed sensor - Short circuit to ground (C.20.B.95.80 - G.30.B.53) 73
CS540, CS640, CS520, CS660
Sensing system Ground speed sensor - Short circuit to B+ (C.20.B.95.80 - G.30.B.54) 80
CS540, CS640, CS520, CS660
Sensing system Ground speed sensor - Open circuit (C.20.B.95.80 - G.30.B.50) 87
CS540, CS640, CS520, CS660
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C.20.B / 4
POWER TRAIN - TRANSMISSION Mechanical
TRANSMISSION Mechanical - Torque (C.20.B - D.20.A.10)

CS540, CS640, CS520, CS660
Nut on drive shaft 150-170 Nm (111-125 lb ft)

Nut on input shaft 150-170 Nm (111-125 lb ft)
TRANSMISSION Mechanical - Special tools (C.20.B - D.20.A.40)

CS540, CS640, CS520, CS660

Ring nut wrench (Metric 45 mm) 380001074
50030182 1
TRANSMISSION Mechanical - General specification (C.20.B -

D.40.A.10)
CS520
CS520
Differential ratio 18/71
Differential lock Yes/No
Gear ratio
1st gear ratio 18/58
2nd gear ratio 35/62
3rd gear ratio 59/48
Maximum input speed (high idle) 2363
Maximum input speed (full load) 1933
Maximum input torque 634 Nm (468 lb ft)
Maximum output speed (high idle) 736
Maximum output torque 2 x 4029 Nm (2973 lb ft)
Maximum power 136 kW
Brake disc diameter 360 mm (13 in)
Approximately total weight 370 kg (816 lb)
12130 1 02/07/2004
C.20.B / 5

D.40.A.10)
CS540, CS640, CS520, CS660
CS540 - CS640
Gear ratio

D.40.A.10)
CS660
CS660
Gear ratio
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C.20.B / 6
TRANSMISSION Mechanical - Mechanical schema (C.20.B -

C.20.A.10)
CS540, CS640, CS520, CS660
ZDA7759B 1
Traction gearbox
1st gear : 1 - 4 - 6 - 8 2nd gear : 2 - 5 - 6 - 8

3th gear : 3 - 7 - 6 - 8
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C.20.B / 7
TRANSMISSION Mechanical - Sectional view (C.20.B - C.10.A.30)

CS540, CS640, CS520, CS660
ZDA7759A 1
Traction gearbox
1 Input shaft 2 Drive shaft

3 Differential 4 Differential shafts
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C.20.B / 8
Shaft Input shaft - Overview (C.20.B.43.01 - C.10.A.10)

CS540, CS640, CS520, CS660
ZDA7717A 1
Input shaft
1 Input shaft 2 Oil baffle plate

3 Threaded shaft 4 Flange
5 O-ring 6 Seal
7 Bearing 8 Shims
9 Cover
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C.20.B / 9
Shaft Input shaft - Exploded view (C.20.B.43.01 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7730A 1
Input shaft
1 Nut 2 Lock washer

3 Washer 4 Bearing
5 Washer 6 Gear
7 Needle bearing 8 Retaining ring
9 Washer 10 Selector ring
11 Ball 12 Spring
13 Selector housing 14 Input shaft
12130 1 02/07/2004
C.20.B / 10
Shaft Input shaft - Sectional view (C.20.B.43.01 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDA7729A 1
Input shaft
1 Nut 2 Lock washer

3 Washer 4 Bearing
5 Washer 6 Gear
7 Needle bearing 8 Retaining ring
9 Washer 10 Selector ring
11 Ball 12 Spring
13 Selector housing 14 Input shaft
12130 1 02/07/2004
C.20.B / 11
Shaft Drive shaft - Overview (C.20.B.43.02 - C.10.A.10)

CS540, CS640, CS520, CS660
ZDA7716A 1
Drive shaft
1 Cover shaft 2 Seal

3 Shims 4 O-ring
5 Drive shaft
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C.20.B / 12
Shaft Drive shaft - Exploded view (C.20.B.43.02 - C.10.A.20)

CS540, CS640, CS520, CS660
ZEIL04CS0079G0B 1
Drive shaft
12130 1 02/07/2004
C.20.B / 13
1 Seal 2 Bearing
3 Drive shaft 4 Gear
5 Needle bearings 6 Selector ring
7 Selector housing 8 Ball
9 Spring 10 Washer
11 Retaining ring 12 Gear
13 Needle bearings 14 Washer
15 Bearing 16 Washer
17 Lock washer 18 Nut
12130 1 02/07/2004
C.20.B / 14
Shaft Drive shaft - Sectional view (C.20.B.43.02 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDA7720A 1
Drive shaft
1 Seal 2 Bearing
3 Drive shaft 4 Gear
5 Needle bearings 6 Selector ring
7 Selector housing 8 Spring
9 Ball 10 Washer
11 Retaining ring 12 Gear
13 Needle bearings 14 Washer
15 Bearing 16 Washer
17 Lock washer 18 Nut
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C.20.B / 15
Shaft Differential shaft - Exploded view (C.20.B.43.03 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA3445A 1
Differential shaft and differential
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C.20.B / 16
1 Differential shaft 2 Seal

3 Retaining ring 4 Bearing
5 Flange 6 Bearing
7 O-ring 8 Differential shaft
9 Flange 10 Bearing
11 Differential 12 Spring
13 Differential lock collar 14 Retaining ring
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C.20.B / 17
Differential - Sectional view (C.20.B.50 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDA3393A 1
Differential
1 Bearing 2 Bearing
3 Bolt 4 Lock plate
5 Differential housing 6 Differential output gear
7 Planet gear shaft 8 Planet gear
9 Differential output gear 10 Ring gear
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C.20.B / 18
Differential - Exploded view (C.20.B.50 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA3391A 1
Differential
1 Bearing 2 Bearing
3 Bolt 4 Lock plate
5 Differential housing 6 Differential output gear
7 Planet gear shaft 8 Planet gear
9 Differential output gear 10 Ring gear
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C.20.B / 19
Shifting disc system - Exploded view (C.20.B.60 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7829A 1
Shifting disc
12130 1 02/07/2004
C.20.B / 20
1 Shaft 2 Shifting disc

3 Shifting disc housing 4 Seal
5 Handle 6 Roll pin
7 O-ring 8 Bushing
9 Allen screw 10 Pin
11 Spring 12 Seal
13 Plug
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C.20.B / 21
Cover - Exploded view (C.20.B.75 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA3444A 1
Cover
12130 1 02/07/2004
C.20.B / 22
1 Bolt 2 Special bolt

3 Support 4 Cover
5 Seal 6 Pin
7 Lever 8 Retaining ring
9 Differential lock control shaft 10 O-ring
11 Retaining ring 12 Fork
12130 1 02/07/2004
C.20.B / 23
TRANSMISSION Mechanical - Remove (C.20.B - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the traction gearbox cover plate (3).

IMPORTANT: Before removing any components, secure
the machine safely in place by placing adequate wedges
against both traction and steering wheels.
ZDA6061A 1
2. On the left-hand side, remove the cover (2) by

loosening the bolts.
ZDA7604A 2
3. Remove the cover (3) by loosening the bolts.
ZDA7605A 3
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C.20.B / 24
4. Remove the cover (4) by loosening the bolts.
ZDA7819A 4
5. Loosen the hose clamps (4) and (5).
ZDA7814A 5
6. Support the hydrostatic motor (1) and loosen the

four nuts (2). (only two nuts are shown)
Pull the hydrostatic motor (1) out of the gearbox.
NOTE: In some cases it will be necessary to remove the
LHS traction wheel for taking the hydrostatic motor out
of the gearbox.
ZDA7815A 6
7. Disconnect the hand brake cable (1) by removing

the bolt.
ZDA7816A 7
12130 1 02/07/2004
C.20.B / 25
8. Disconnect the differential lock cable (2).

Disconnect the combine speed sensor (3).
ZDA6035B 8
9. Disconnect the gearshift bar (4).
ZDA7817A 9
10. Disconnect the sleeves (1) on both sides of the

traction gearbox.
Disconnect the brake lines (2) and remove the
supports (3), on both sides of the traction gearbox.
CAUTION
Z022 - The gearbox is heavy (380 kg [838 lbs]). Take
extreme caution when removing the gearbox! Use a
supporting device which can handle this weight!
ZDA7349B 10
11. Loosen the three bolts (1) at both sides of traction

gearbox.
Lower the traction gearbox and remove it from
underneath the combine.
ZDA7818A 11
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C.20.B / 26
TRANSMISSION Mechanical - Disassemble (C.20.B - F.10.A.25)

CS540, CS640, CS520, CS660
1. Remove the cover. Housing - Remove (C.20.B.74

- F.10.A.10)
2. Remove the differential shafts and differential.
Shaft Differential shaft - Remove (C.20.B.43.03 -
F.10.A.10) and Differential - Remove (C.20.B.50 -
F.10.A.10)
3. Remove the selector shaft. Shifting disc system
Selector shaft - Remove (C.20.B.60.40 -
F.10.A.10)
4. Remove the drive shaft. Shaft Drive shaft -
Remove (C.20.B.43.02 - F.10.A.10)
5. Remove the input shaft. Shaft Input shaft -
Remove (C.20.B.43.01 - F.10.A.10)
6. Remove the shifting disc. Shifting disc system
Disc - Remove (C.20.B.60.41 - F.10.A.10)
7. Disassemble and assemble the differential.
Differential - Disassemble (C.20.B.50 - F.10.A.25)
and Differential - Assemble (C.20.B.50 -
F.10.A.20)
8. Disassemble and assemble the drive shaft. Shaft
Drive shaft - Disassemble (C.20.B.43.02 -
F.10.A.25) and Shaft Drive shaft - Assemble
(C.20.B.43.02 - F.10.A.20)
9. Disassemble and assemble the input shaft. Shaft
Input shaft - Disassemble (C.20.B.43.01 -
F.10.A.25) and Shaft Input shaft - Assemble
(C.20.B.43.01 - F.10.A.20)
12130 1 02/07/2004
C.20.B / 27
TRANSMISSION Mechanical - Assemble (C.20.B - F.10.A.20)

CS540, CS640, CS520, CS660
1. Install the shifting disc. Shifting disc system Disc

- Install (C.20.B.60.41 - F.10.A.15)
2. Install the input shaft. Shaft Input shaft - Install
(C.20.B.43.01 - F.10.A.15)
3. Install the drive shaft. Shaft Drive shaft - Install
(C.20.B.43.02 - F.10.A.15)
4. Install the selector shaft. Shifting disc system
Selector shaft - Install (C.20.B.60.40 - F.10.A.15)
5. Install the differential shafts and the differential.
Differential - Install (C.20.B.50 - F.10.A.15)
6. Install the cover. Housing - Install (C.20.B.74 -
F.10.A.15)
12130 1 02/07/2004
C.20.B / 28
Shaft Input shaft - Remove (C.20.B.43.01 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the selector fork (2) from the input shaft.
ZDA7737A 1
2. Remove the threaded shaft (3), refer to Shaft Input

shaft - Exploded view (C.20.B.43.01 - C.10.A.20),
and the oil baffle plate (1) by turning out the cap
screws (2).
ZDA7718A 2
3. Remove the ring (1).

NOTE: The ring (1) is only applied with 100 cc hydro
motor. A 100 cc hydro motor centers directly in the
gearbox housing and the outer Metric 16 threads are used
for fixation of the hydro motor.
ZDA3337A 3
12130 1 02/07/2004
C.20.B / 29
4. Remove the three Allen screws (1).
ZDA3339A 4
5. Remove the seal housing (2) with the lip-seal and

the O-ring.
ZDA3338A 5
6. Remove the five nuts and the washers (1).
ZDA3340A 6
7. Remove the cover (1).

IMPORTANT: Keep the shims and the O-ring with the
cover.
12130 1 02/07/2004
C.20.B / 30
8. Support the input shaft on a hoist to avoid from

falling into the gearbox.
Drive the shaft in the direction shown and remove
the bearing outer ring (1).
ZDA7739A 8
9. Pull the bearing (1) from the drive shaft.

Remove the drive shaft out of the gearbox.
ZDA3343A 9
10. If necessary, remove the bearing outer ring (1).
ZDA3344A 10
12130 1 02/07/2004
C.20.B / 31
Shaft Input shaft - Disassemble (C.20.B.43.01 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Unlock the lock washer (2).

Remove the nut (1), the lock plate (2) and the
washer (3).
ZDA3406A 1
2. Remove the gear (2), the bearing (1) and the

washer between the two parts with a puller.
ZDA7731A 2
3. Remove the needle bearings (1).

Remove the selector ring (2) at the same time
remove the two balls (3) and the springs behind it.
NOTE: The balls (3) are spring loaded, do not loose them.
ZDA3408A 3
12130 1 02/07/2004
C.20.B / 32
4. Remove the retaining ring (1).

Remove the washer (2) and the selector housing (3)
at the same time.
ZDA7735A 4
12130 1 02/07/2004
C.20.B / 33
Shaft Input shaft - Assemble (C.20.B.43.01 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Install the selector housing (3).

Install the washer (4).
ZDA7732A 1
2. Install the retaining ring (1).
ZDA7735B 2
3. Install the two springs and the two balls (3) and at
the same time install the selector ring (2).
NOTE: Be careful not to loose the balls.
ZDA3408A 3
4. Install the needle bearings (1).
12130 1 02/07/2004
C.20.B / 34
5. Install the gear (1).

ZDA7733A 4
6. Heat the bearing (4) to 80 °C (176 °F) and install it

on the input shaft.
Install the lock washer (2).
Install the nut (1) and tighten to a torque between
150 - 170 Nm (111 - 125 lb ft.).
Secure the nut (1) by bending a lip of the lock
washer in one of the notches of the nut.
ZDA3406A 5
12130 1 02/07/2004
C.20.B / 35
Shaft Input shaft - Install (C.20.B.43.01 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the shims (2) of 1.5 mm (1/16 in) and the

O-ring (3) on the cover (1).
ZDA3414A 1
2. Install the bearing outer ring (1).
ZDA3344A 2
3. Install the cover (2) with the shims and the O-ring
and tighten the five nuts (1).
ZDA3340B 3
12130 1 02/07/2004
C.20.B / 36
4. Support the input shaft on a hoist and bring it into

the traction gearbox.
Heat the bearing (1) to 80 °C (176 °F) and install it
on the input shaft.
IMPORTANT: Bearing has to lean completely against its
shoulder on the input shaft.
ZDA3415A 4
ZDA7827A 5
6. If necessary, replace the seal (1) and the O-ring

(2) on the ring (4).
ZDA3434A 6
7. Install the seal ring (4).
ZEIL04CS0077A0B 7
12130 1 02/07/2004
C.20.B / 37
8. Install with Loctite 242 the three Allen screws (1)

and tighten them.
ZDA3339A 8
9. Install the ring (1).
ZDA3337A 9
10. Install a dial the gauge (2) in the gearbox housing

and locate the probe perpendicular against the side
of the gear (1).
Apply a load in one direction and oscillate the shaft
several times while the load is applied.
Set the dial gauge to zero.
Apply the load in the opposite direction, oscillate
and read the axial movement of the shaft.
Make three measurements at 120 ° of the input
shaft. Calculate the arithmetic mean of the three
readings, it should be 0-0.03 mm (0-0.001 in).
If required, adjust the shims. To decrease the axial
movement, decrease the quantity of shims.
IMPORTANT: Be sure to measure on the gear (1) as the ZDA7741A 10
other gears are mounted on needle bearings.
12130 1 02/07/2004
C.20.B / 38
11. Install the selector fork (1).
ZDA7736A 11
12. Install the oil baffle plate (1) and insert threaded
shaft (2), (Fig.13). Install the bolts (2).
ZDA7718A 12
13. After tightening of the nuts, rotate the input shaft

and verify that the oil baffle does not interfere with
the input shaft.
ZDA3340C 13
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C.20.B / 39
Shaft Drive shaft - Remove (C.20.B.43.02 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the five nuts and the washers (1) of the

cover (2).
ZEIL04CS0076A0B 1
2. Remove the cover (2).

IMPORTANT: Keep the shims and O-ring with the cover.
ZDF0368A 2
3. Remove the shifting disc, refer to Shifting disc

system Disc - Remove (C.20.B.60.41 - F.10.A.10)
or remove first the plug (13) and the spring (11),
refer to Shifting disc system - Exploded view
(C.20.B.60 - C.10.A.20)
Bring the shifting disc in it’s highest position by
turning shifting disc housing (3) out until the shifting
disc block against the gearbox housing.
ZDF0249B 3
12130 1 02/07/2004
C.20.B / 40
4. Remove the drive shaft (1) and the selector fork

(2) with a hoist.
ZDA7828A 4
5. If necessary, remove the bearing outer ring (1).
ZDA7738A 5
12130 1 02/07/2004
C.20.B / 41
Shaft Drive shaft - Disassemble (C.20.B.43.02 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Unlock the lock washer (2).

Remove the nut (1), the lock washer (2) and the
washer (3).
ZDA3396A 1
2. Remove the gear (2) and the bearing (1) together

with a puller.
ZDA7722A 2
ZDA7723A 3
12130 1 02/07/2004
C.20.B / 42
4. Remove the selector ring (1) at the same time

remove the two balls (2) and the springs behind it.
NOTE: The balls (2) are spring loaded, do not loose them.
ZDA7724A 4
5. Remove the retaining ring (3) and the washer.

6. Remove the housing (1) and the gear (2).
ZDA7725A 5

Remove the bearing (1) on the other side.
NOTE: The bearing (1) will be damaged when it is
removed.
ZDA3401A 6
12130 1 02/07/2004
C.20.B / 43
Shaft Drive shaft - Assemble (C.20.B.43.02 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Heat the bearing (1) to 80 °C (176 °F) and install it

on the drive shaft.
ZDA7726A 1

Install the gear (2).
Install the selector housing (3).
ZDA7727A 2

Install the two springs.
Install the two balls (2) on the springs and at the
same time install the selector ring (1).
NOTE: Be careful not to loose the balls.
ZDA7724A 3
12130 1 02/07/2004
C.20.B / 44
ZDA7723A 4
5. Install the gear (2).

Install the washer (3) and heat the bearing (4) to
80 °C (176 °F) and install it on the drive shaft.
ZDA7728A 5
6. Install the washer (3).

Install the lock washer (2).
Install the nut (1) and tighten it to a torque between
150 - 170 Nm (111 - 125 lb ft) by using the ring nut
wrench. (refer to TRANSMISSION Mechanical -
Special tools (C.20.B - D.20.A.40)).
Secure the nut (1) by bending a lip of the lock
washer in one of the notches of the nut.
ZDA3396A 6
12130 1 02/07/2004
C.20.B / 45
Shaft Drive shaft - Install (C.20.B.43.02 - F.10.A.15)

CS540, CS640, CS520, CS660
ZDA7738A_29 1
2. If necessary, replace the seal (2).

Install the bearing outer ring (3).
Install the shims (4) of 1.5 mm (1/16 in) and the
O-ring (5) on the cover (1).
ZDA3438A 2
3. Support the drive shaft (1) on a hoist and bring it

into the traction gearbox.
NOTE: If the shifting disc is installed, the selector fork (2)
should be installed together with the drive shaft.
ZDA7828A 3
12130 1 02/07/2004
C.20.B / 46
4. Install the cover (2) with shims, seals and bearing

outer ring, and tighten the nuts (1).
ZEIL04CS0076A0B 4
5. Install a dial the gauge (2) on the gearbox housing

and locate the probe perpendicular against the side
of the gear (1).
Apply a load in one direction and oscillate the shaft
several times while the load is applied.
Set the dial gauge to zero.
Apply the load in the opposite direction, oscillate
and read the axial movement of the shaft.
Make three measurements at 120 ° of the
intermediate shaft. Calculate the arithmetic mean of
the three readings, it should be 0-0.03 mm (0-0.001
in).
If required, adjust the shims. To decrease the axial
movement, decrease the quantity of shims.
ZDF0247A 5
IMPORTANT: Be sure to measure on the gear (1) as the
other gears are mounted on needle bearings.
12130 1 02/07/2004
C.20.B / 47
Shaft Differential shaft - Remove (C.20.B.43.03 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Drain the oil through the plug (1).

Remove brake shoes and brake discs on both sides
of the traction gearbox (refer to Master cylinder -
Static description (D.30.C.27 - C.30.A.20).
NOTE: The traction gearbox contains 19 liters (5 US gal)
oil.
ZDA7843A 1
2. On the right-hand side differential shaft, remove the

seal (1).
NOTE: It is not possible to remove the seal (1) without
damaging it.
ZDA3262A 2
ZDA3263A 3
12130 1 02/07/2004
C.20.B / 48
4. Pull out the shaft (1) together with the bearing (2).
ZDA3264A 4
5. Remove the six nuts and the washers (1).

Remove the two bolts and the washers (2).
ZDA3265A 5
6. Install the two bolts (1) (Metric 10 x 60) and remove

the housing (2).
ZDA3266A 6
7. Hang the differential to prevent it from falling into

the gearbox.
Remove the four nuts and the washers (1).
Remove the two Allen screws (2).
Remove the two bolts and the washers (3).
ZDF0404A 7
12130 1 02/07/2004
C.20.B / 49
8. Screw in the two bolts (2) to push the bearing

housing (1) out of the gearbox housing.
ZDF0403A 8
9. Remove the differential, using a adequate lifting

device.
ZDF0369A 9
10. Remove the oil baffle plate (1).
ZDA3443A 10
12130 1 02/07/2004
C.20.B / 50
Shaft Differential shaft - Disassemble (C.20.B.43.03 - F.10.A.25)

CS540, CS640, CS520, CS660
1. If necessary, remove the seal (1) on the left-hand

side differential shaft housing.
NOTE: It is not possible to remove the seal (1) without
damaging it.
ZDA3270A 1
2. Remove the retaining ring behind the seal (1) and

take out the differential half shaft (2).
3. Remove the bearing (1) from the shaft (2).
ZDA3271A 2
12130 1 02/07/2004
C.20.B / 51
Shaft Differential shaft - Assemble (C.20.B.43.03 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Install the bearing (1) on the shaft (2).

Install the shaft (2) with the bearing in the differential
half shaft housing.
Install the retaining ring.
ZDA3271A 1
2. Install the new seal (1).
ZDA3270A 2
3. Replace the O-ring (1).
ZDA3272A 3
12130 1 02/07/2004
C.20.B / 52
4. On the right-hand side differential shaft housing,

replace the O-ring (1).
ZDA3273A 4
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C.20.B / 53
Differential - Disassemble (C.20.B.50 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Remove the bearing (1).
ZDA3387A 1
2. Turn the differential and remove the bearing (2).
ZDA3388A 2
3. Unlock the lock plates (1) and remove the bolts (2)
and the lock plates.
ZDA3389A 3
12130 1 02/07/2004
C.20.B / 54
4. Remove the upper part (1) of the differential

housing.
ZDA3390A 4
5. Remove the differential output gear (1).

Remove the two planet gear shafts (3) with the
planet gears (4).
Remove the differential output gear (2).
ZDA3392A 5
12130 1 02/07/2004
C.20.B / 55
Differential - Assemble (C.20.B.50 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Install the differential output gears and the planet

gears with the planet gear shafts.
Install the differential housing (1).
NOTE: The two castings of the housing are machined
together and are marked in this position. When
reassembling, make sure that these marks are towards
each other.
ZDA3390A 1
2. Install the lock plates (1) and the bolts (2).

Secure the bolts (2) by bending the lock plates
against a flat side of the bolts.
ZDA3389A 2
3. Install the bearing (2).
ZDA3388A 3
12130 1 02/07/2004
C.20.B / 56
4. Install the bearing (1).
ZDA3387A 4
12130 1 02/07/2004
C.20.B / 57
Differential - Install (C.20.B.50 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the oil baffle plate (1).
ZDA3443A 1
2. Support the differential on a hoist and bring it into

the gearbox.
ZDF0369A 2
3. Bring the differential lock collar(1) and the spring (2)

into the half shaft housing (3).
ZDA7826A 3
12130 1 02/07/2004
C.20.B / 58
4. Install the both half shafts housings (1) and (2) and
tighten all the nuts (3) and (4) simultaneously.
ZDA7734A 4
5. Install the shaft (1) with the bearing (2).
ZDA3264A_32 5
ZDA3263A_33 6
7. Install the new seal (1).
ZDA3262A_34 7
12130 1 02/07/2004
C.20.B / 59
Differential lock command - Adjust (C.20.B.51 - F.45.A.01)

CS540, CS640, CS520, CS660
1. Keep the cable (2) at the bottom under tension with

the hand and tighten with the bolt (3) so that the
support (4) can be installed to the lever (5).
ZDA6035C 1
2. Push on the differential pedal (1) until the connected

position is obtained.
NOTE: Sometimes is it necessary to lift up and rotate one
traction tyre, using a adequate lifting device.
ZDA7476A 2
3. Adjust in this (connected) position the pedal (1)

against the stop (7) by turning the bolt (6).
ZDF0306A 3
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C.20.B / 60
4. After adjusting turn the bolt (6) with a extra 1/2 of a

turn and secure it with the nut (8).
ZDF0305A 4
12130 1 02/07/2004
C.20.B / 61
Shifting disc system Selector shaft - Remove (C.20.B.60.40 -

F.10.A.10)
CS540, CS640, CS520, CS660
ZDA3326A 1
ZDA3327A 2
3. Remove the selector shaft (3).
ZDF0244A 3
12130 1 02/07/2004
C.20.B / 62
Shifting disc system Selector shaft - Install (C.20.B.60.40 - F.10.A.15)

CS540, CS640, CS520, CS660
1. If necessary, replace the O-rings in the gearbox

housing where the selector shaft (3) is installed.
Install the selector shaft (3). Put the selector forks
on the shaft.
ZDF0244A 1
ZDA3327A 2
ZDA3326A_31 3
12130 1 02/07/2004
C.20.B / 63
Shifting disc system Disc - Remove (C.20.B.60.41 - F.10.A.10)

CS540, CS640, CS520, CS660
NOTE: It is possible to remove and to install the shifting disc without disassembly of the gearbox shafts.
1. Remove the plug (13).
ZDF0250B 1
2. Loosen the three Allen screw (9).

Remove the bushing (8) with the spring (11) and
the pin completely.
Remove the roll pin (6).
Remove the lever (5) and the shifting disc with the
shaft from the inside of the gearbox.
Remove the shifting disc housing (3).
ZDF0249B 2
3. If necessary, replace the O-ring (4), inside the

housing (2).
ZDF0256A 3
12130 1 02/07/2004
C.20.B / 64
Shifting disc system Disc - Install (C.20.B.60.41 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the O-ring (7) with NEW HOLLAND AMBRA

GR 75 MD GREASE, refer to Shifting disc system
- Exploded view (C.20.B.60 - C.10.A.20).
Install the bushing (8) and tighten the three Allen
screws (9).
Install the shifting disc housing (3).
ZDF0245A 1
2. Before install, add NEW HOLLAND AMBRA GR

75 MD GREASE onto the holes (4) of the shifting
disc (2).
ZDF0267A 2
3. Install the shifting disc and the shaft (1) from the
inside of the gearbox and install the lever (6).
Install the roll pin (5), using a hammer.
NOTE: In case the input shaft, the drive shaft and the
differential are not assembled into the gearbox, bring the
shifting disc in it’s highest position by turning the shifting
disc housing (3) out until the shifting disc blocks against
the gearbox housing. Proceed with step 4 until 6 after
installation of the input shaft.
ZEIL04CS0074A0B 3
4. Apply Loctite 242 to the shifting disc housing at (3)

and tighten the housing with a torque between 190 -
210 Nm (140 - 155 lb ft).
IMPORTANT: Verify if the followers on the selector forks
fix into the notches of the shifting disc.
12130 1 02/07/2004
C.20.B / 65
5. Install the pin (10) (Shifting disc system -

Exploded view (C.20.B.60 - C.10.A.20)) and the
spring (11).
ZDF0249A 4
6. Install the plug (13) with the seal (12) (Shifting disc
system - Exploded view (C.20.B.60 - C.10.A.20))
Tighten the plug (13).
Apply Loctite 242 to the thread of the tap (14) before
installing.
ZDF0250A 5
12130 1 02/07/2004
C.20.B / 66
Shifting disc system Bar - Adjust (C.20.B.60.42 - F.45.A.01)

CS540, CS640, CS520, CS660
1. Block the wheels adequately to prevent runaway of

the combine.
Loosen the nut (1).
Remove the cotter pin (2) and the pin (3) to
disconnect the gear shift bar (4).
ZDA7835A 1
2. Place the gear shift lever (1) in the second gear.
ZDA7842A 2
3. Adjust the handle (2) on the traction gearbox in

vertical position (second gear).
ZDA7841A 3
12130 1 02/07/2004
C.20.B / 67
4. Adjust the fork (4) of the gear shift bar until the pin
(3) (fig.5) can be installed.
ZDA7839A 4
5. Install the pin (3) and the washers.

Install the cotter pin (2).
Tighten the nut (1).
ZDA7835B 5
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C.20.B / 68
Cover - Remove (C.20.B.75 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove all the bolts (1) and the cover (2).
ZDA7834A 1
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C.20.B / 69
Cover - Disassemble (C.20.B.75 - F.10.A.25)

CS540, CS640, CS520, CS660
1. If necessary, remove the bolt (1) and the differential

lock control lever (2).
NOTE: Refer to Cover - Exploded view (C.20.B.75 -
C.10.A.20). Removal of the differential control lever (7)
and the differential lock control shaft (9) is necessary only
if the fork (12) and/or the O-ring (10) need to be replaced.
ZDA3258A 1
2. Remove the retaining ring (1) and the differential

lock control shaft (2).
ZDA3259A 2
3. Replace the O-ring (1).

Remove the retaining ring (2) to remove the fork (3).
ZDA3260A 3
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C.20.B / 70
Cover - Assemble (C.20.B.75 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Install the fork (3) and fix with the retaining ring (2).
ZDA3260A 1
2. Install the differential lock control shaft (2), and

install the retaining ring (1).
ZDA3259A 2
3. Install the differential lock control lever (2) and fix

with the bolt (1).
ZDA3258A 3
12130 1 02/07/2004
C.20.B / 71
Cover - Install (C.20.B.75 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the drain plug and fill the traction gearbox

with oil. Refer to the Operator’s Manual section
"Lubrication".
Install the cover (2) with a new seal.
IMPORTANT: Be sure the differential lock control fork is
positioned correctly.
ZDA7834A 1
2. Tighten all the bolts (1).
12130 1 02/07/2004
C.20.B / 72
Sensing system Ground speed sensor - Short circuit to ground

(C.20.B.95.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E101 - GROUNDSPEED SENSOR (B7) SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty groundspeed sensor
Solution:
1. Check the groundspeed sensor connector X27, CCM connector X142, and the in-line harness connector X26.

2. Check the sensor for a short to ground.
A. Disconnect connector X27. Check between the component side of connector X27 pin 1, circuit (112)
(ZW) and ground. If a short to ground is indicated, remove and replace the groundspeed sensor.

3. Check for a short to ground.
A. Disconnect connector X142. Check between connector X27 pin 2, circuit (099) (GE) and ground. If a
short to ground is indicated, repair or replace the harness as required.
B. If the harness is okay, continue to step 4.

4. Check the groundspeed sensor.
A. Connect connector X142. Remove the groundspeed sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect groundspeed sensor to connector X32. Turn the key start ON.
Check if the error code E119 is now also displayed. If error code E119 is displayed, replace the
groundspeed sensor.
B. If error code E119 is not displayed, download the correct level of software. If the fault re-occurs, remove

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
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C.20.B / 73

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 74
55_a3cs016 1
12130 1 02/07/2004
C.20.B / 75

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 76
vfil04cs0026h0a 2
12130 1 02/07/2004
C.20.B / 77

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 78
vfil04cs0027h0a 3
12130 1 02/07/2004
C.20.B / 79
Sensing system Ground speed sensor - Short circuit to B+

(C.20.B.95.80 - G.30.B.54)
CS540, CS640, CS520, CS660
E102 - GROUNDSPEED SENSOR (B7) SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the groundspeed sensor connector X27 and the in-line harness connector X26.

2. Check for a short to +12 Volts.
A. Disconnect connector X27. Turn the key start ON. Measure the voltage between connector X27 pin 2,
circuit (099) (GE) and ground. If the voltage indicated is greater than +8 Volts, repair or replace the
harness as required.
B. If the voltage indicated is approximately +8 Volts, download the correct level of software. If the fault

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12130 1 02/07/2004
C.20.B / 80

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 81
55_a3cs016 1
12130 1 02/07/2004
C.20.B / 82

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 83
vfil04cs0026h0a 2
12130 1 02/07/2004
C.20.B / 84

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 85
vfil04cs0027h0a 3
12130 1 02/07/2004
C.20.B / 86
Sensing system Ground speed sensor - Open circuit (C.20.B.95.80 -

G.30.B.50)
CS540, CS640, CS520, CS660
E103 - GROUNDSPEED SENSOR (B7) OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty groundspeed sensor
Solution:
1. Check the groundspeed sensor connector X27, CCM connector X142, and the in-line harness connector X26.

A. Disconnect connector X27. Check between connector X27 pin 1, circuit (112) (ZW) and ground. If an
open circuit is indicated, repair or replace the harness as required.

3. Check for +8 Volts.
A. Turn the key start ON. Check between connector X27 pin 2, circuit (099) (GE) and ground. If the voltage
indicated is approximately +8 Volts, continue to step 4.
B. If no voltage is indicated, continue to step 5.

4. Check the sensor for an open circuit.
A. Turn the key start OFF. Remove the groundspeed sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect groundspeed sensor to connector X32. Turn the key start ON.
Check if the error code E121 is now also displayed. If error code E121 is displayed, replace the
groundspeed sensor.
A. Turn the key start OFF. Disconnect the connector X142. Check between connector X27 pin 2, circuit
(099) (GE) and X142 pin 13, circuit (099) (GE). If an open circuit is indicated, repair or replace the
B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace
the CCM.
12130 1 02/07/2004
C.20.B / 87

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 88
55_a3cs016 1
12130 1 02/07/2004
C.20.B / 89

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 90
vfil04cs0026h0a 2
12130 1 02/07/2004
C.20.B / 91

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12130 1 02/07/2004
C.20.B / 92
vfil04cs0027h0a 3
12130 1 02/07/2004
C.20.B / 93
Index
POWER TRAIN - C
Cover - Assemble (C.20.B.75 - F.10.A.20) 71

CS540, CS640, CS520, CS660
Cover - Disassemble (C.20.B.75 - F.10.A.25) 70
CS540, CS640, CS520, CS660
Cover - Exploded view (C.20.B.75 - C.10.A.20) 22
CS540, CS640, CS520, CS660
Cover - Install (C.20.B.75 - F.10.A.15) 72
CS540, CS640, CS520, CS660
Cover - Remove (C.20.B.75 - F.10.A.10) 69
CS540, CS640, CS520, CS660
Differential - Assemble (C.20.B.50 - F.10.A.20) 56
CS540, CS640, CS520, CS660
Differential - Disassemble (C.20.B.50 - F.10.A.25) 54
CS540, CS640, CS520, CS660
Differential - Exploded view (C.20.B.50 - C.10.A.20) 19
CS540, CS640, CS520, CS660
Differential - Install (C.20.B.50 - F.10.A.15) 58
CS540, CS640, CS520, CS660
Differential - Sectional view (C.20.B.50 - C.10.A.30) 18
CS540, CS640, CS520, CS660
Differential lock command - Adjust (C.20.B.51 - F.45.A.01) 60
CS540, CS640, CS520, CS660
Sensing system Ground speed sensor - Open circuit (C.20.B.95.80 - G.30.B.50) 87
CS540, CS640, CS520, CS660
Sensing system Ground speed sensor - Short circuit to B+ (C.20.B.95.80 - G.30.B.54) 80
CS540, CS640, CS520, CS660
Sensing system Ground speed sensor - Short circuit to ground (C.20.B.95.80 - G.30.B.53) 73
CS540, CS640, CS520, CS660
Shaft Differential shaft - Assemble (C.20.B.43.03 - F.10.A.20) 52
CS540, CS640, CS520, CS660
Shaft Differential shaft - Disassemble (C.20.B.43.03 - F.10.A.25) 51
CS540, CS640, CS520, CS660
Shaft Differential shaft - Exploded view (C.20.B.43.03 - C.10.A.20) 16
CS540, CS640, CS520, CS660
Shaft Differential shaft - Remove (C.20.B.43.03 - F.10.A.10) 48
CS540, CS640, CS520, CS660
Shaft Drive shaft - Assemble (C.20.B.43.02 - F.10.A.20) 44
CS540, CS640, CS520, CS660
Shaft Drive shaft - Disassemble (C.20.B.43.02 - F.10.A.25) 42
CS540, CS640, CS520, CS660
Shaft Drive shaft - Exploded view (C.20.B.43.02 - C.10.A.20) 13
CS540, CS640, CS520, CS660
Shaft Drive shaft - Install (C.20.B.43.02 - F.10.A.15) 46
CS540, CS640, CS520, CS660
Shaft Drive shaft - Overview (C.20.B.43.02 - C.10.A.10) 12
CS540, CS640, CS520, CS660
12130 1 02/07/2004
C.20.B / 94
Shaft Drive shaft - Remove (C.20.B.43.02 - F.10.A.10) 40
CS540, CS640, CS520, CS660
Shaft Drive shaft - Sectional view (C.20.B.43.02 - C.10.A.30) 15
CS540, CS640, CS520, CS660
Shaft Input shaft - Assemble (C.20.B.43.01 - F.10.A.20) 34
CS540, CS640, CS520, CS660
Shaft Input shaft - Disassemble (C.20.B.43.01 - F.10.A.25) 32
CS540, CS640, CS520, CS660
Shaft Input shaft - Exploded view (C.20.B.43.01 - C.10.A.20) 10
CS540, CS640, CS520, CS660
Shaft Input shaft - Install (C.20.B.43.01 - F.10.A.15) 36
CS540, CS640, CS520, CS660
Shaft Input shaft - Overview (C.20.B.43.01 - C.10.A.10) 9
CS540, CS640, CS520, CS660
Shaft Input shaft - Remove (C.20.B.43.01 - F.10.A.10) 29
CS540, CS640, CS520, CS660
Shaft Input shaft - Sectional view (C.20.B.43.01 - C.10.A.30) 11
CS540, CS640, CS520, CS660
Shifting disc system - Exploded view (C.20.B.60 - C.10.A.20) 20
CS540, CS640, CS520, CS660
Shifting disc system Bar - Adjust (C.20.B.60.42 - F.45.A.01) 67
CS540, CS640, CS520, CS660
Shifting disc system Disc - Install (C.20.B.60.41 - F.10.A.15) 65
CS540, CS640, CS520, CS660
Shifting disc system Disc - Remove (C.20.B.60.41 - F.10.A.10) 64
CS540, CS640, CS520, CS660
Shifting disc system Selector shaft - Install (C.20.B.60.40 - F.10.A.15) 63
CS540, CS640, CS520, CS660
Shifting disc system Selector shaft - Remove (C.20.B.60.40 - F.10.A.10) 62
CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Assemble (C.20.B - F.10.A.20) 28
CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Disassemble (C.20.B - F.10.A.25) 27
CS540, CS640, CS520, CS660
CS520
CS540, CS640, CS520, CS660
CS660
TRANSMISSION Mechanical - Mechanical schema (C.20.B - C.20.A.10) 7
CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Remove (C.20.B - F.10.A.10) 24
CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Sectional view (C.20.B - C.10.A.30) 8
CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Special tools (C.20.B - D.20.A.40) 5
CS540, CS640, CS520, CS660
TRANSMISSION Mechanical - Torque (C.20.B - D.20.A.10) 5
CS540, CS640, CS520, CS660
12130 1 02/07/2004
C.20.B / 95
12130 1 02/07/2004
C.20.B / 96
POWER TRAIN - C
TRANSMISSION Hydrostatic - 20.F
CS540
CS640
CS520
CS660
12131 1 02/07/2004
C.20.F / 1
Contents
POWER TRAIN - C
TECHNICAL DATA
TRANSMISSION Hydrostatic - Special tools (C.20.F - D.20.A.40) 4

CS540, CS640, CS520, CS660
Oil cooler by-pass

Oil cooler by-pass - General specification (C.20.F.19 - D.40.A.10) 4
CS540, CS640, CS520, CS660
Pump
Pump - General specification (C.20.F.20 - D.40.A.10) 4
CS520
CS540, CS640
CS660
Motor
Motor - General specification (C.20.F.28 - D.40.A.10) 5
CS520
CS540, CS640
CS660
FUNCTIONAL DATA
TRANSMISSION Hydrostatic - Hydrostatic schema (C.20.F - C.20.B.25) 7

CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Hydrostatic symbol (C.20.F - C.20.C.25) 9
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Static description (C.20.F - C.30.A.20) 10
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Dynamic description (C.20.F - C.30.A.10) 12
CS540, CS640, CS520, CS660
Control valve
Control valve - Static description (C.20.F.13 - C.30.A.20) 15
CS540, CS640, CS520, CS660
Relief valve
Relief valve - Static description (C.20.F.16 - C.30.A.20) 18
CS540, CS640, CS520, CS660
Pump
Pump - Static description (C.20.F.20 - C.30.A.20) 20
CS540, CS640, CS520, CS660
12131 1 02/07/2004
C.20.F / 2
Pump - Component identification (C.20.F.20 - C.40.C.20) 21
CS540, CS640, CS520, CS660
Motor
Motor - Static description (C.20.F.28 - C.30.A.20) 22
CS540, CS640, CS520, CS660
Motor - Component identification (C.20.F.28 - C.40.C.20) 23
CS540, CS640, CS520, CS660
SERVICE
TRANSMISSION Hydrostatic - Service instruction (C.20.F - F.10.A.05) 24

CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Filling (C.20.F - F.60.A.10) 26
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Start up (C.20.F - F.35.A.41) 30
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Pressure test (C.20.F - F.40.C.30) 32
CS540, CS640, CS520, CS660
Shuttle spool valve

Shuttle spool valve - Remove (C.20.F.14 - F.10.A.10) 36
CS540, CS640, CS520, CS660
Shuttle spool valve - Install (C.20.F.14 - F.10.A.15) 37
CS540, CS640, CS520, CS660
Relief valve
Relief valve - Replace (C.20.F.16 - F.10.A.30) 38
CS540, CS640, CS520, CS660
Pump
Pump - Remove (C.20.F.20 - F.10.A.10) 39
CS540, CS640, CS520, CS660
Pump - Install (C.20.F.20 - F.10.A.15) 41
CS540, CS640, CS520, CS660
Motor
Motor - Remove (C.20.F.28 - F.10.A.10) 44
CS540, CS640, CS520, CS660
Motor - Install (C.20.F.28 - F.10.A.15) 46
CS540, CS640, CS520, CS660
DIAGNOSTIC
TRANSMISSION Hydrostatic - Troubleshooting (C.20.F - G.40.A.10) 48

CS540, CS640, CS520, CS660
12131 1 02/07/2004
C.20.F / 3
POWER TRAIN - TRANSMISSION Hydrostatic
TRANSMISSION Hydrostatic - Special tools (C.20.F - D.20.A.40)

CS540, CS640, CS520, CS660
Description Tool number

Pressure gauge 0-40 bar (2 off) (0-600 PSI) 380000552
Pressure gauge 0-150 bar (1 off) (0-2500 PSI) 293243#
Pressure gauge 0-600 bar (2 off) (0-9000 PSI) 293246#
Pressure gauge hose (5 off) 380000545
# Part of kit 292870
Minimess connector, size EMA 3-9/16 in or 84021707
Parker Diagnostic (PD361)-9/16 in 86596853
Minimess connector (tube side) M16x2 or PD361 procure locally
Quick release connector (tube side) 380000543
Oil cooler by-pass - General specification (C.20.F.19 - D.40.A.10)

CS540, CS640, CS520, CS660
Manufacturer Parker
Maximum operating pressure 17.2 bar (249 psi)
Cooler port opening temperature 46-52 °C (114.8-125.6 °F)
Cooler port fully open temperature 63 °C (145.4 °F)
Maximum operating temperature 91 °C(195.8 °F)
Minimum operating temperature -34 °C (-29.2 °F)
Maximum flow rate 227 l/min. (60 gal/min)
Relief valve pressure 2.8 - 3.4 bar (40.6-49.3 psi)
Pump - General specification (C.20.F.20 - D.40.A.10)

CS520
Manufacturer Sauer Danfoss

Type 90 Series closed circuit
Control Mechanical displacement control (non linear)
Frame size 75
Direction of rotation right-hand rotation
Displacement 75 cc/rev
Minimum speed at low idle (1200) 1710 rpm
Rated speed at 2100 rpm 3000 rpm
Maximum speed at high idle (2205) 3150 rpm
Charge pump displacement 20 cc/rev
Charge pump pressure 26 bar (377 psi)
- High pressure limiter setting: delta p: 420 bar (6092 psi)
absolute : 450 bar (6527 psi)
- High pressure relief setting: delta p: 450 bar (6527 psi)
absolute: 480 bar (6962 psi)
Flow at rated speed 210 l/min (55 gal/min)
12131 1 02/07/2004
C.20.F / 4

CS540, CS640

Frame size 100

CS660

Frame size 130
Motor - General specification (C.20.F.28 - D.40.A.10)

CS520

Type 90 Series fixed displacement, closed circuit
Frame size 100
Direction of rotation Bi-directional
Displacement 100 cc/rev (6.1 in³/rev)
12131 1 02/07/2004
C.20.F / 5
Rated speed (loaded) 2100 rpm

Maximum speed (High idle) 2360 rpm
Case pressure - maximum continuous 3 bar (43.5 psi)
Case pressure - maximum (cold start) 5 bar (72.5 psi)

CS540, CS640

Frame size 100

CS660

Frame size 100
12131 1 02/07/2004
C.20.F / 6
TRANSMISSION Hydrostatic - Hydrostatic schema (C.20.F -

C.20.B.25)
CS540, CS640, CS520, CS660
ZEIL04CS0078H0B 1
Hydrostatic drive schematic
12131 1 02/07/2004
C.20.F / 7
LEGEND
1. Pressure filter
2. Charge pressure sensor (switch)
3. Displacement control valve
4. Orifice check valve
5. Servo valve feedback linkage
6. Hydrostatic pump servo cylinders
7. Multi function valve (forward)
7a. Pressure limiter (420 bar) (6090 psi)
7b. High pressure relief valve (450 bar) (6525 psi)
7c. Bypass valve
7d. Charge pressure check valve
8. Charge pump pressure relief valve
9. Hydrostatic pump with variable displacement
10. Charge pump
11. Multi function valve (reverse)
11a. Pressure limiter (420 bar) (6090 psi)
11b. High pressure relief valve (450 bar) (6525 psi)
11c. Bypass valve
11d. Charge check valve
12. Thermo valve
13. Suction filter
14. Hydrostatic oil cooler
15. Reservoir
16. Hydrostatic motor with fixed displacement
17. Shuttle spool valve
18. Hydrostatic motor flushing relief valve
19. Check valves
20. High pressure line (forward)
21. High pressure line (reverse)
A. High pressure port (motor: forward drive - pump: reverse drive)
B. High pressure port (motor: reverse drive - pump: forward drive)
S. Suction port
M1. Measure point - High pressure port (Pump: reverse - Motor: forward) ("B" motor) (fitting 9/16 in)
M2. Measure point - High pressure port (Pump: forward - Motor: reverse) ("A" motor) (fitting 9/16 in)
M3.Measure point - charge pressure after filter, connected to charge pressure sensor (switch) (fitting 9/16 in)
M4. Measure point - pressure to main servo cylinder forward (fitting 9/16 in)
M5. Measure point - pressure to main servo cylinder reverse (fitting 9/16 in)
M6. Measure point - charge pressure before filter (fitting 9/16 in)
M8. Measure point - flushing pressure
L1. Case drain port
L2. Case drain port
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C.20.F / 8
TRANSMISSION Hydrostatic - Hydrostatic symbol (C.20.F -

C.20.C.25)
CS540, CS640, CS520, CS660
Symbol Description
Displacement control valve
Orifice check valve
Hydrostatic pump with variable displacement and fixed capacity

charge pump
Charge pressure relief valve
Pressure filter (charge pressure)
Thermo valve
Shuttle spool valve
Non-return check valve
Multi function valve - Pressure limiter valve set at 420 bar (delta p)
Hydrostatic motor with fixed displacement
Fixed flow flushing relief valve
Hydrostatic oil cooler
Charge pressure switch
12131 1 02/07/2004
C.20.F / 9
TRANSMISSION Hydrostatic - Static description (C.20.F - C.30.A.20)

CS540, CS640, CS520, CS660
The CS Combine hydrostatic system contains four main components, an oil reservoir, hydrostatic pump, charge
pump, and drive motor.Some machines are equipped with an optional powered steering axle (PRA).
Oil reservoir
From series 1320 to 1360: A double oil reservoir is fitted for the hydraulic and hydrostatic system. The reservoir is
located at the upper left-hand side of the machine behind the engine compartment. A baffle in the tank separates
the hydraulic and hydrostatic oils. The left-hand side (1) contains the oil for the hydrostatic system. The right-hand
side (2) contains the oil for the hydraulic system.
ZDA7346A 1
From series 1364: A single oil reservoir is fitted for the hydraulic and hydrostatic system. The reservoir is located
at the upper left-hand side of the machine behind the engine compartment. Fill the oil for the hydraulic and
hydrostatic system through the inlet (1).
ZEIL04CS0100A0B 2
Hydrostatic pump
The hydrostatic pump (1) is driven by a belt directly from the engine. The hydrostatic pump assembly includes the
charge pump (2), charge pressure filter (3) and charge pressure sensor (switch) (4). The hydrostatic pump also
houses the servo displacement valve and multi function valves.
Charge pump
The charge pump (2) is mounted to the rear of the hydrostatic pump assembly (1) and houses the charge pressure
relief valve.
ZDA6045B 3
12131 1 02/07/2004
C.20.F / 10
Hydrostatic drive motor

The hydrostatic motor (1) is mounted to the main transmission and is driven hydraulically by the hydrostatic pump.
The hydrostatic motor supplies the drive input to the main transmission.
ZDA7347A 4
Powered Rear Axle (PRA)
Each wheel of the powered steering axle is driven independently by its own hydrostatic motor (2). Each motor is
driven hydraulically by the hydrostatic pump and controlled by a control valve.
ZDA8167A 5
12131 1 02/07/2004
C.20.F / 11
TRANSMISSION Hydrostatic - Dynamic description (C.20.F -

C.30.A.10)
CS540, CS640, CS520, CS660
The CS Combine hydrostatic system contains a reservoir, Charge pump, Hydrostatic pump, Drive motor and
optional powered steering axle.
The hydrostatic pump assembly incorporates the charge pump and is driven by a drive belt from the engine.
Neutral
With the engine running and the hydrostatic lever in neutral the charge pump receives oil from the reservoir (15)
through a 100 micron filter screen (13) into the charge pump (10). The oil is then pumped through filter (1), to the
multi function valves (7) and (11). The charge pressure will open the check valves, (7d) and (11d), allowing charge
pressure to fill the hydrostatic pump (9), high pressure lines, (20) and (21) and drive motor (16). Charge pressure oil
will also fill the servo valve feedback linkage (5), and the servo cylinders (6).
The hydrostatic pump swash plate stands square to the input shaft. With no axial movement of the pistons there is
no flow of high pressure oil in the high pressure line (20).
When the charge pump pressure in the system increases to 26 bar (377 psi) the charge pressure relief valve (8) will
open and oil will flow into the hydrostatic pump casing through the thermostatically controlled oil cooler (14), to
the reservoir (15).
If the oil temperature is below 49 °C (120 °F) the oil will flow directly to the reservoir (15) when the oil temperature is
above 49 °C (120 °F) the thermo valve (12) diverting the oil flow through the oil cooler (14).
Forward
When the hydrostatic lever is moved forward, the displacement control valve (3) will move to the position of the
hydrostatic lever. The oil can then flow to the forward servo cylinder (6).
The charge pressure oil acting on the forward servo cylinder (6) will move the hydrostatic pump swash plate
creating axial movement of the pistons increasing the pressure in the forward high pressure line (20) towards the
drive motor (16).
The increased pressure in the forward high pressure line (20) will create rotational movement of the drive motor
pistons, causing the drive motor output shaft to turn in the forward direction. The oil will return by the return line
(21) to the hydrostatic pump (9).
Also the increase in pressure will close the forward multi function valve charge check valve (7d) preventing the
charge pressure circuit receiving drive pressure from the hydrostatic pump (9).
The charge pump (10) will continue to charge the reverse high pressure line (21) through the reverse multi
function valve charge check valve (11d) to replace the oil used for lubrication and flushing and any oil lost through
internal leakage.
The return oil from the drive motor (16) is going back to the pump.
If there is more than a 7 bar (101.5 psi) pressure difference across the drive motor (16) the drive pressure from
the hydrostatic pump (9), moves shuttle spool valve (17) in the drive motor assembly (16) connecting the return
line (21) to the flushing relief valve (18).
The flushing relief valve (18) will open at a lower pressure than the charge pressure relief valve (8) causing some of
the charge pressure oil to flow through the flushing relief valve (18) to the drive motor case drain. The oil will then
flow to the oil cooler through the pump case drain, cooling the motor and pump bodies.
If the resistance on the drive motor (16) increases (machine travelling up hill) then the pressure in the forward high
pressure line (20) will increase. As the pressure reaches 420 bar (6090 psi) (delta p) the pressure limiter valve (7a)
will open allowing oil to flow to the hydrostatic pump reverse servo cylinder piston (6) reducing the swash plate
angle and pump flow, protecting the hydrostatic system from over pressure.
The pressure on the reverse servo cylinder piston (6) is limited by the check valve (19). This valve connect the
relief flow from the pressure limiter valve (7a) to the charge pressure circuit.
If the pressure in the high pressure line exceeds +/- 480 bar (6962 psi) (shock) then the relief valve (7b) will open
allowing oil to flow directly from the high pressure line (20) into the return line (21) through the charge check
valve (11d) (the pump is by-passed in this instance).
When carrying out a hydrostatic stop (rapid movement of the hydrostatic control lever from drive to neutral) the drive
motor (16) will operate as the pump, this will make the pump (9) operate as the motor, dissipating brake energy
towards the diesel engine. The maximum brake pressure in forward mode is limited by the function valve (11).
Reverse
When the hydrostatic lever is moved to reverse the system operates the same as in forward other than high
pressure line (20) becomes the return line and high pressure line (21) becomes the drive line.
In reverse braking is achieved by the motor acting as a pump and its pressure is controlled by the multi function
valve (7).
12131 1 02/07/2004
C.20.F / 12
ZEIL04CS0078H0B 1
Hydrostatic drive schematic
12131 1 02/07/2004
C.20.F / 13
12131 1 02/07/2004
C.20.F / 14
Control valve - Static description (C.20.F.13 - C.30.A.20)

CS540, CS640, CS520, CS660
The multi function valve has four functions, and three different valves. The valves with in the multi function valve are
as follows:
• A charge pressure check valve to keep the system full of oil.
• A pressure limiter valve to make the work pressure (delta p) does not exceed 420 bar (6090 psi).
• A high pressure relief valve to protect the system from shock loads above 450 bar (6525 psi) (delta p).
The multi function valve also includes a bypass valve to enable the vehicle to be moved at very low speeds for short
distances if an engine failure occurs.The bypass valve is a manually operated valve and oil flow generated by the
drive motor (acting as a pump) is allowed to flow to the suction side of the motor.
A. Bypass actuator
B. Pressure limiter adjustment screw
C. Pressure limiter lock nut
D. Pressure limiter housing
E. Pressure limiter spring
F. Spring seat
G. Check valve carriage
H. High pressure relief/check valve poppet
J. Valve seat
K. Spring
L. Pressure limiter poppet seat
M. Pressure limiter valve poppet
7d -11d. Charge check valve
7a -11a. Pressure limiter (420 bar) (6090 psi)
7b- 11b. High pressure relief valve (450 bar) (6525 psi)
7c -11c. Bypass valve
BSC1328A 1
Multi function valve cross section
12131 1 02/07/2004
C.20.F / 15
ZDF0409A 2
Multi function valve schematic
Charge check valve (7d) - (11d)

When the charge pressure in port (Y) becomes higher than the pressure in the high pressure port (X) and enough
to overcome the tension of spring (B) carrier (A) will move to he left taking along poppet (C). Oil from the charge
pump will flow from port (Y) to port (X) filling the system.
BSC1298A 3
Pressure limiter (7a) - (11a)
When high pressure exceeds 420 bar (6090 psi), poppet (D) will move to the left, compressing spring (E) due to the
pressure behind the poppet pressurized oil will flow from port (X) into port (Z) to the main servo cylinder. The main
servo cylinder will then move the swash plate of the hydrostatic pump towards neutral when the transmission is in
drive mode and towards maximum displacement when the transmission is in brake mode.
BSC1298B 4
12131 1 02/07/2004
C.20.F / 16
High pressure relief valve (7b) - (11b)

When the pressure limiter opens at 420 bar (6090 psi) a certain oil flow will escape through port (Z). If the pressure
from the high pressure port (X) increases to 450 bar (6525 psi) due to shock loading, the pressure difference which
is created over the plunger (C) will move the plunger towards the left against spring (B) and high pressure oil will
be allowed to flow from port (X) to port (Y). In this phase, the pressure limiter function remains active as well (oil
keeps flowing from port (X) to port (Z)).
BSC1298C 5
Bypass valve (7c) - (11c)
When the bypass actuator (H) is turned 31/2 turns counter-clockwise the force on poppet (J) is reduced. This sets
the pressure limiter valve at near zero setting. When the pump is not turning but pressure is generated in the high
pressure lines by the motor (motor acting as a pump), poppet (J) moves to the left, oil flows from port (X) through
opening (G) to port (Z). Plunger (C) will also move easily to the left allowing the pressurized oil from port (X) to flow
to port (Y). As pressure increases to the valve which equals spring (B) plunger (C) will move to the left and allowing
oil to flow directly from port (X) to port (Y) (oil keeps flowing from port (X) to port (Z)).
BSC1298D 6
12131 1 02/07/2004
C.20.F / 17
Relief valve - Static description (C.20.F.16 - C.30.A.20)

CS540, CS640, CS520, CS660
Shuttle spool valve (17)

When the pressure in either of the drive lines increases (forward or reverse selected) pilot pressure will act on one
side of the shuttle spool valve, moving the spool valve to connect the return line to the flushing relief valve and
pressure release solenoid valve.
Flushing relief valve (18)
With the motor running in forward or reverse the pressure in the return line will act on the flushing relief valve
opening the valve to case drain. Drive motor shuttle spool and flushing valve
• Drive motor (16)
• Shuttle spool valve (17)
• Flushing relief valve (18)
ZDF0411A 1
12131 1 02/07/2004
C.20.F / 18
ZDF0410A 2
12131 1 02/07/2004
C.20.F / 19
Pump - Static description (C.20.F.20 - C.30.A.20)

CS540, CS640, CS520, CS660
The variable displacement pump is designed to convert an output power from the engine into hydraulic power. The
input shaft turns the pump cylinder which contains a ring of pistons. The pistons run against a tilted plate (swash
plate), this causes the pistons to compress the hydraulic oil which converts the input energy into the hydraulic oil.
The high pressure oil then provides power to the motor.
The swash plate angle can be varied by the control piston, altering the swash plate angle varies the displacement of
the oil. A larger angle causes greater displacement, a smaller angle reduces the displacement per revolution which
in turn will result in a higher and also respectively lower speed of the motor.
ZDF0375A 1
Hydrostatic pump
1 Charge pump 2 Cradle hold down

3 Slider block 4 Servo piston
5 Servo arm (cradle adjust lever) 6 Servo valve
7 Feed back 8 Cradle bearing
9 Cradle guide 10 Cradle
11 Cradle return position
12131 1 02/07/2004
C.20.F / 20
Pump - Component identification (C.20.F.20 - C.40.C.20)

CS540, CS640, CS520, CS660
Each pump has a name plate attached to the housing. The name plate will include the model number, model
code and serial number.
Model Code (A)
The Sauer Danfoss model code defines the specific build configuration of each unit and must be used when
ordering spare parts or a new pump.
Model Number (B)
The Sauer Danfoss model number is used by the factory in manufacturing. A new unit can be ordered by the
model number.
Serial Number (C)
The Sauer Danfoss serial number identifies the location and date of manufacture and the unit sequence in the
build.The letter coding indicates the location of original assembly “A" indicates assembly in Ames, Iowa, USA “N"
indicates assembly in Neumunster, Germany.The first number (two digits) indicates the year of manufacture. For
example, a unit built in 2001 would have the number “01" in this space.The second number (two digits) indicates
the calendar week of manufacture, from week 1 to week 52.The third number (five digits) is the sequential build
number identifying the specific unit.
Pump identification name plate
ZDF0417A 1
Explanation of model code (A)
29_29-2_13 2
90 Series 90, closed circuit

R Right hand (clockwise rotation)
100 Maximum displacement 100 cc/rev (6.1 in³/rev)
NA Manual displacement control - non linear
5 Pressure limiter function in ports A and B
NN No auxiliary mounting pad
80 Twin ports
L Integrated pressure filtering (long)
3 No mechanical displacement limitation
T6 Tapered shaft end (without key)
E Charge pump displacement 20 cc/rev (1.22 in³/rev)
03 Control orifice diameter P= 0.81 mm (0.032 in) TA/TB =1.3 mm (0.051 in)
GBA Noise optimized valve plate
42 420 bar (6090 psi) high pressure setting port A
42 420 bar (6090 psi) high pressure setting port B
26 26 bar (377 psi)
12131 1 02/07/2004
C.20.F / 21
Motor - Static description (C.20.F.28 - C.30.A.20)

CS540, CS640, CS520, CS660
The fixed displacement motor is designed to convert input hydraulic power into output torque, it operates in reverse
to the hydrostatic pump. The high pressure hydraulic oil enters through the input port, the oil pressure increases
behind the pistons causing them to rotate down the swash plate (path of least resistance). As the piston rides up the
swash plate again, the hydraulic oil is allowed to exit through the outlet port. The spinning pistons are housed in a
cylinder which is connected to the output shaft, the output torque can be applied to the transmission input.
ZDF0376A 1
Hydrostatic motor
1 Swash plate 2 Piston

3 Flushing relief valve 4 Cylinder block
5 Shuttle spool valve
12131 1 02/07/2004
C.20.F / 22
Motor - Component identification (C.20.F.28 - C.40.C.20)

CS540, CS640, CS520, CS660
Each motor has a name plate attached to the housing. The name plate will include the model number, model
code and serial number.
Model Code (A)
The Sauer Danfoss model code defines the specific build configuration of each unit and must be used when
ordering spare parts or a new pump.
Model Number (B)
The Sauer Danfoss model number is used by the factory in manufacturing. A new unit can be ordered by the
model number.
Serial Number (C)
The Sauer Danfoss serial number identifies the location and date of manufacture and the unit sequence in the
build.The letter coding indicates the location of original assembly “A" indicates assembly in Ames, Iowa, USA “N"
indicates assembly in Neumunster, Germany.The first number (two digits) indicates the year of manufacture. For
example, a unit built in 2001 would have the number “01" in this space.The second number (two digits) indicates
the calendar week of manufacture, from week 1 to week 52.The third number (five digits) is the sequential build
number identifying the specific unit.
Motor identification name plate
ZDF0416A 1
Explanation of model code (A)
29_29-2_15 2
90 Series 90, closed circuit

M Fixed displacement bi-directional rotation
100 Maximum displacement 100 cc/rev (6.1 in3/rev)
NC Standard
0 Standard
N Standard
7 Axial ports (SAE J518C code 62)
N Standard
0 Standard
F1 Splined shaft - 13 teeth - pitch 8/16
W With special loop flushing valve for increased flushing
00 Not applicable
NNN Not applicable
00 Not applicable
00 Not applicable
GO Loop flushing flow (22 l/min @ 25 bar (360 PSI))
12131 1 02/07/2004
C.20.F / 23
TRANSMISSION Hydrostatic - Service instruction (C.20.F -

F.10.A.05)
CS540, CS640, CS520, CS660
WARNING
Z023 - The machine must be operating to check system pressures. Make certain that everyone is clear of
the machine and all gauges are secured.
CAUTION
Z020 - Raise the combine drive wheels off the ground to prevent the combine from travelling uncontrolled
when making adjustments. Be sure to use suitable blocking or jack stands to support the weight of the
combine.
CAUTION
Z015 - If equipped with powered rear axle make certain the switch is off.
NOTE: Although the pump is shown removed for clarity, most repairs and adjustments can be made without
removing the hydrostat.
1. PUMP
Major repairs are those which require the removal of
the end cap or side cover. Repairs of this type are to
be performed only by Sauer-Sundstrand Authorized
Service Centers and/or original equipment
manufacturers who have personnel adequately
trained to perform these repairs. Performing major
repairs on the Series 90, 100 cc, Hydrostatic
Transmission may affect the unit warranty status.
12131 1 02/07/2004
C.20.F / 24
2. MOTOR
Major repairs are those repairs which require
the removal of the end cap or side cover.
Repairs of this type are to be performed only by
Sauer-Sundstrand Authorized Service Centers
and/or original equipment manufacturers who have
personnel adequately trained to perform these
repairs. Performing major repairs on the Series
90 Hydrostatic Transmission may affect the unit
warranty status, thus the branch service manager
should be consulted prior to such an undertaking.
Cleanliness is a primary means of assuring
satisfactory hydraulic motor life, on either new or
repaired units. Cleaning parts by using a clean
solvent wash and air drying is usually adequate. As
with any precision equipment, all parts must be kept
free of foreign materials and chemicals. Protect all
exposed sealing surfaces and open cavities from
damage and foreign material.
During the assembly of the Series 90 variable motor,
all surfaces, which have relative motion between
two parts, should be coated with a film of clean
hydraulic oil. This will assure that these surfaces
will be lubricated during start-up.
Replace all O-rings and gaskets. Lightly lubricate all
O-rings with clean petroleum jelly prior to assembly.
All gasket sealing surfaces must be cleaned prior to
installing new gaskets.
12131 1 02/07/2004
C.20.F / 25
TRANSMISSION Hydrostatic - Filling (C.20.F - F.60.A.10)

CS540, CS640, CS520, CS660
To filling the hydrostatic system after repair or replacement of hydrostatic components, proceed as follows:
NOTE: Before installing a new motor or a new pump, shipment oil should be drained from the new pump or motor
case.
IMPORTANT: Oil quality and cleanliness is of utmost importance for the reliability and life of the hydrostatic system.
Deviation of the described oil specification may lead to severe damage and void the warranty!
1. Put suitable wheel chocks in front and behind the
front wheels to prevent the machine from moving.
For machines not equipped with powered rear axles
also put blocks in front and behind the rear wheels.
2. Remove the transmission drive shaft couplings (1)
and (2) (Fig.1 and 2).
CAUTION
M948 - Before disconnecting the drive shafts, secure
the machine in place by using adequate wheel chocks
against the front and rear of both traction and steering
wheels.
ZDA7349A 1
3. Make sure the couplings are secured to the drive

shafts.
ZDA7348A 2
4. Disconnect the fuel stop solenoid electrical

connector (4) to prevent the engine from running
during cranking.
ZDA6075B 3
12131 1 02/07/2004
C.20.F / 26
5. Remove the jam nut (1) and (2) and disconnect the
control cable (4) from the settle arm (7). (see fig.5)
ZDA7642B 4
6. Adjust with the nuts (5) and (6) in such a way that
in neutral position of the multi-function handle and
the pump you can easily fix the control cable to the
settle arm (7) of the pump without moving this last
one.
NOTE: Apply Loctite 270 onto the nuts (5) and (6).
ZDA7669A 5
7. Reinstall the control cable (4) onto the settle arm

and secure it with the nut (2) and the jam nut (1)
with a torque between 10 - 12 Nm (7.4 - 8.9 lb ft).
ZDA7642B_36 6
8. From series: 1320 to 1360: Fill the hydrostatic

system with oil through the oil reservoir inlet (1) up
to the maximum. Use hydrostatic oil as described
in the CS Operator’s Manual, “SECTION 4 -
LUBRICATION AND MAINTENANCE".
ZDA7346B 7
12131 1 02/07/2004
C.20.F / 27
9. From series: 1364: Fill the hydrostatic system

with oil through the oil reservoir inlet (1) up to
the maximum. Use hydrostatic oil as described
in the CS Operator’s Manual, “SECTION 4 -
LUBRICATION AND MAINTENANCE".
ZEIL04CS0100A0B 8
10. Loosen the suction line (5) at the pump until oil
leaks out.
Retighten the suction line (5).
ZDA6045C 9
11. Loosen the hydrostatic motor drain plug (1).
ZDA7347A_37 10
12. Loosen the return hose between the hydrostatic

pump and the thermostatic valve at the coupling (2).
Fill the system at (2) with oil through until oil leaks
out of the hydrostatic motor.
ZDA7352A 11
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C.20.F / 28
13. Install and tighten the hydrostatic motor drain plug

(1), (Fig.10) to a torque of 34 Nm (25 lb ft.) and
continue to fill up the pump to obtain maximum oil
level in the pump housing.
14. Connect and tighten the hose between the
hydrostatic pump and the thermostatic valve at port
(2). Tighten it with a torque between 110 - 120 Nm.
(81 - 88.5 lb ft)
Next operation: TRANSMISSION Hydrostatic - Start up (C.20.F - F.35.A.41)
12131 1 02/07/2004
C.20.F / 29
TRANSMISSION Hydrostatic - Start up (C.20.F - F.35.A.41)

CS540, CS640, CS520, CS660
To start-up the hydrostatic system after repair or replacement of hydrostatic components, proceed as follows:
Prior operation: TRANSMISSION Hydrostatic - Filling (C.20.F - F.60.A.10)
NOTE: Before installing a new motor or a new pump, shipment oil should be drained from the new pump or motor
case.
IMPORTANT: Oil quality and cleanliness is of utmost importance for the reliability and life of the hydrostatic system.
Deviation of the described oil specification may lead to severe damage and void the warranty!
1. Install pressure gauges (range 0-500 bar) (0-7250

psi) to the hydrostatic pump test port (3)
= (port M2: High pressure forward)
For machines equipped with powered rear axles,
use a suitable hydraulic jack and raise the rear axle.
Support on rear axle on suitable axle stands.
CAUTION
Z013 - For machines equipped with powered rear
axles the rear wheels MUST be clear of the ground.
ZDA7640A 1
2. Place the hydrostatic lever and the gearshift control

in neutral position.
Crank the engine with the starter motor until
a pressure gauge reading of minimum 2.0 bar
(minimum 29 psi) is obtained.
NOTE: Only crank the engine for a maximum of 30
seconds at a time. Wait at least 1 minute before
re-cranking to avoid damaging the starter motor.
3. Fill the reservoir to the maximum level.
4. Connect the fuel stop solenoid connector (4).
ZDA6075B 2
12131 1 02/07/2004
C.20.F / 30
5. Start and run the engine at low idle until a minimum

pressure gauge reading of 20 bar (290 psi) is
obtained.
CAUTION
M583 - Make sure everyone is clear of the machine
before starting the engine.
CAUTION
SM100A - Never operate the engine in a closed
building. Proper ventilation is required under all
circumstances.
6. Gearshift to neutral and engine speed on low idle.

Position the hydrostatic lever at half stroke for two
minutes, both forward and reverse.
7. Gearshift remains in neutral and engine speed on
high idle. Position the hydrostatic lever at maximum
stroke for two minutes, both forward and reverse.
8. Check the oil level, add oil if necessary.
9. Check for oil leaks.
10. Measure and write down the gauge pressure
(forward) at full stroke in the reverse position. This
pressure (flush pressure) should be between 21 -
29 bar (305 - 421 psi).
11. Position the hydrostatic lever in neutral position and
the engine at high idle. Measure and write down the
gauge pressure. This pressure (charge pressure)
should be between 1 - 3 bar (14.5 - 43.5 psi) higher
than the value measured in step 10
12. Gearshift into third gear and engine speed on
high idle. Apply both brake pedals firmly. Apply
maximum stroke on the hydrostatic lever in forward
position for a maximum of 10 seconds. Pressure
should be 430 - 460 bar (6237-6672 psi).
13. Switch off the engine.
14. Remove the gauge.
15. Check the oil level, add oil if necessary. Check for
oil leaks.
16. For machines equipped with powered rear axle
continue to remove the air from the system, Refer to
Motor - Static description (D.14.E.28 - C.30.A.20).
17. For machines not equipped with powered rear axle,
install the transmission drive shafts and tighten the
retaining bolts.
12131 1 02/07/2004
C.20.F / 31
TRANSMISSION Hydrostatic - Pressure test (C.20.F - F.40.C.30)

CS540, CS640, CS520, CS660
WARNING
M953 - Gauges, fittings and hoses MUST have operating pressure ratings of a least 25 percent higher than
the highest pressure of the circuit being tested.
CAUTION
Z010 - Block the front and rear wheels with suitable blocks so the machine cannot move. Make sure
everyone is clear of the machine before starting the engine.
CAUTION
SM100A - Never operate the engine in a closed building. Proper ventilation is required under all
circumstances.
1. Pressure testing
Various pressure and vacuum gauge readings are
necessary for troubleshooting problems with the
main hydrostatic drive system.
To check the high pressure settings of the multi
function valves it will be necessary to connect high
pressure gauges to the system.
Measuring the charge pump inlet vacuum assist in
locating restrictions in the suction lines and filter
screen.
Case pressure readings will assist in locating
restrictions in the return lines, oil cooler and filter.
The pump and motor charge pressure must be
checked and recorded during pressure testing.
To make sure accurate pressure readings are
obtained, the system must be at normal operating
temperature and at full rated engine speed.
IMPORTANT: The interior of all test equipment must
be exceptionally clean before being used to test the
hydrostatic drive system. Make sure the test equipment
is purged of all oil and foreign material to avoid
contamination of the hydrostatic drive system.
12131 1 02/07/2004
C.20.F / 32
2. Charge pressure
The minimum allowable charge pressure for the
pump is 26 bar (377 psi) above the case drain
pressure. To determine the actual charge pressure,
subtract the case drain pressure from the charge
pressure reading.
To check the charge pressure install a test port
instead of the pressure sensor (1). Use a 150 bar
(2500 psi) pressure gauge. The measured pressure
at this test point is charge pressure plus case drain
pressure.
ZDA6045D 1
Charge pressure @ 50 °C(122 °F) oil temperature (High idle)

Neutral 26 bar (+/- 2 bar)
377 psi (+/- 39 psi)
Forward Pressure drop 1 - 3 bar with respect to neutral (14.5 - 43.5 psi)
Reverse Pressure drop 1 - 3 bar with respect to neutral (14.5 - 43.5 psi)
Forward brakes on Minimum 20 bar (290 psi)
12131 1 02/07/2004
C.20.F / 33
3. Servo pressure
Gauges should be installed into the ports M4 and
M5 (see arrows) of the control unit, located at the
bottom of the pump.
In neutral the pressure should be equal. As
the forward or reverse is activated a pressure
rise on one gauge should be countered with a
corresponding pressure drop on the other gauge.
This test may determine the reason for a unit that
creeps whilst the lever is in neutral. Joining the
ports together should stop the creeping, if this is the
case adjust the neutral position within the control
unit. If the unit still creeps when the ports are joined
the pump will require replacement.
ZDA7642C 2
Servo pressure @ 50 °C(122 °F) oil temperature

Forward servo Reverse servo
Neutral Forward = reverse servo = +/- 2 bar (29 psi)
Forward Maximum value = charge pressure Maximum 3 bar (case pressure)
Reverse Maximum 3 bar (case pressure) (43.5 Maximum value = charge pressure
psi)
12131 1 02/07/2004
C.20.F / 34
4. High pressure
The high pressure is determined by the two multi
function valves. The relief valve setting is 450 bar
(delta p) (6525 psi). The pressure limiter will start
to destroke the pump servo cylinders at 420 bar
(delta p) (6090 psi).
The high pressure can be checked at pump test
ports (3),“M2" for forward and test port “M1" for
reverse drive (fig.3)
The pressure can also be checked at the drive
motor. Forward high pressure at test port “A" and
reverse high pressure at test port “B" (fig.4).
CAUTION ZDA7640A_38 3
Z010 - Block the front and rear wheels with suitable
blocks so the machine cannot move. Make sure
everyone is clear of the machine before starting the
engine.
CAUTION
SM100A - Never operate the engine in a closed
building. Proper ventilation is required under all
circumstances.
ZDA7347B 4
Forward pressure (High idle) @ 50 °C(122 °F) oil temperature

Neutral Charge pressure 26 bar (+/- 2 bar) 377 PSI (+/-29 psi)
Forward maximum 430-460 bar (7236-6672 psi)
Reverse pressure (High idle) @ 50 °C(122 °F) oil temperature

Neutral Charge pressure 26 bar (+/- 2 bar) 377 PSI(+/-29 psi)
Reverse maximum 430-460 bar (7236-6672 psi)
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C.20.F / 35
Shuttle spool valve - Remove (C.20.F.14 - F.10.A.10)

CS540, CS640, CS520, CS660
NOTE: The motor is shown removed for clarity.

1. Secure the combine so that it can not move.
2. Drain the oil from the hydrostatic oil reservoir
through the drain hose.
3. Remove the cartridges (1) and (2) from both sides
of the valve.
10013273 1
4. Push the spool (1) out of the motor.
10013274 2
5. Inspect parts for damage or foreign material.
20015831 3
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C.20.F / 36
Shuttle spool valve - Install (C.20.F.14 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the flushing valve spool (1).
10013276 1
2. Install the cartridges (1) on each end of the spool

tighten wit a torque to 41 Nm (30 lb ft).
20015831_46 2
Next operation: TRANSMISSION Hydrostatic - Filling (C.20.F - F.60.A.10) and TRANSMISSION Hydrostatic -
Start up (C.20.F - F.35.A.41).
12131 1 02/07/2004
C.20.F / 37
Relief valve - Replace (C.20.F.16 - F.10.A.30)

CS540, CS640, CS520, CS660

Drain the oil from the hydrostatic oil reservoir
2. Remove the motor charge pressure relief valve (1).
NOTE: Motor shown removed for clarity.
10013271 1
3. Turn in the new relief valve (1). Tighten the valve to

a torque of 52 Nm (38 lb ft).
10013272 2
Next operation: TRANSMISSION Hydrostatic - Filling (C.20.F - F.60.A.10) and TRANSMISSION Hydrostatic -
Start up (C.20.F - F.35.A.41).
12131 1 02/07/2004
C.20.F / 38
Pump - Remove (C.20.F.20 - F.10.A.10)

CS540, CS640, CS520, CS660
CAUTION

2. Drain the oil from the hydrostatic oil reservoir
NOTE: When disconnecting hydraulic lines, have a
hydraulic oil.
3. Detach the connector (3) from the oil pressure
switch.
ZDA7641A 1
4. Remove the two main high pressure lines (4) and

(5) by turning out the eight bolts.
Disconnect and cap the two flushing/return lines (6).
Remove the suction line (7).
IMPORTANT: Avoid entry of dirt into the hydrostatic lines.
ZDA7639A 2
12131 1 02/07/2004
C.20.F / 39
5. Remove the jam nut (1) and the nut (2).

Loosen the two bolts (3) and remove the control
cable (4).
ZDA7642A 3
6. Release the belt by loosening the lock nut (5).
ZDF0363A 4
7. Securely attach the hydrostatic pump to a suitable

lifting device.
Remove the four bolts (1) and the washers on both
sides of the support. (four bolts are shown)
NOTE: The hydrostatic pump weighs approximately 137
kg (303 lb).
ZDA7643A 5
8. To remove the pump from the support (1), remove

first the pulley by loosening the eight bolts.
Loosen the four nuts (2).
ZDA7644A 6
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C.20.F / 40
Pump - Install (C.20.F.20 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the hydrostatic pump to the support (1) and

tighten the four nuts (2).
Install the pulley and tighten it with the eight bolts.
ZDA7644A_39 1
2. Securely attach the hydrostatic pump to a suitable

lifting device. Raise the pump to his place and turn
on the four bolts, bushing and washers on both
sides (see fig.3).
IMPORTANT: Do not forget to install the drive belt.
ZDA7643A_40 2
3. Tighten the nuts to standard torque.
ZDA7668A 3
12131 1 02/07/2004
C.20.F / 41
4. Install the suction line (7) and tighten the nut (1) with
a torque between 125 - 138 Nm (92 - 102 lb ft).
The torque of the fitting (2) in the pump is between
285 - 313 Nm. (210 - 231 lb ft)
Install the two flushing/return lines (6). Tighten the
two fittings (3) with a torque between 110 - 120 Nm.
(81 - 89 lb ft)
NOTE: The nipple in the pump should be tighten with a
torque between 170 - 187 Nm (125 - 138 lb ft).
ZDA7639B 4
5. Lubricate and install the O-rings into the ends of the

main high pressure lines (4) and (5).
IMPORTANT: Be sure that the high pressure line of port
"A" from the hydrostatic pump is connected with the high
pressure line of port "B" from the hydrostatic motor. (Port
“A" pump = Port “B" motor)
6. Connect the two main high pressure lines (4) and (5)
by installing the eight bolts (8). Tighten those bolts
with a torque between 104 - 114 Nm. (77 - 84 lb ft)
IMPORTANT: Never put any torsion on the flexible hoses
and must be assembled according the neutral bend
radius.
7. Attach the connector (3) to the oil pressure switch.
ZDA7641A_41 5
8. Install the control cable (4) with the two bolts (3),
using Loctite 270. (Omnifit 200M, Permabond 118)
ZDA7642A_42 6
12131 1 02/07/2004
C.20.F / 42
9. Apply also Loctite 270 and adjust the nuts (5) and
(6) in such a way that in neutral position of the
multi-function handle and the pump you can easily
fix the control cable to the settle arm (7) of the pump
without moving this last one.
Install and tighten the nut (2) and the jam nut (1)
(see also fig.6) with a torque between 10 - 12 Nm
(7.4 - 8.9 lb ft).
ZDA7669A_43 7
10. Adjust the tension of the drive belt. Refer to the CS

AND MAINTENANCE"; paragraph headed: “Drive
belts and chains".
Next operation: TRANSMISSION Hydrostatic - Filling (C.20.F - F.60.A.10) and TRANSMISSION Hydrostatic
- Start up (C.20.F - F.35.A.41)
12131 1 02/07/2004
C.20.F / 43
Motor - Remove (C.20.F.28 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Drain the hydrostatic oil reservoir.

NOTE: During removal of the three hydraulic lines, up to
five additional gallons of fluid can be expected. A suitable
container must be positioned under the lines to capture
the residual hydraulic fluid.
2. Remove the traction gearbox cover plate (3).
IMPORTANT: Before removing any components, secure
the machine safely in place by placing adequate wedges
against both traction and steering wheels.
ZDA6061A_44 1
3. Remove the two main high pressure lines (3) by

turning out eight cap screws.
Disconnect the case drain line (4) at the upper
elbow union.
Loosen the lower elbow union (5) and rotate the
elbow 90 degrees.
ZDA7552A 2
4. Support the weight of the motor with a floor jack.

Turn off the four mounting nuts (1). (only two nuts
are shown).
ZDA7553A 3
12131 1 02/07/2004
C.20.F / 44
5. Move the motor away in length axis direction from

the transmission until the spline shaft is disengaged.
Lower the motor from the combine.
10013282 4
12131 1 02/07/2004
C.20.F / 45
Motor - Install (C.20.F.28 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Support the weight of the motor with a floor jack.

Raise the motor into position on the transmission.
Apply grease onto the spline shaft of the motor.
Engage the spline shaft of the motor and push it
into the female spline until the mounting flange is
against the transmission.
10013282 1
2. Turn on the four mounting nuts (1).

NOTE: Apply Loctite 270 onto the four nuts (1).
ZDA7553A 2
3. Torque the nuts to standard torque.

4. Line the case drain elbow (5) up with the case drain
line (4).
Engage the line into the elbow and tighten the fitting.
Tighten the lower elbow fitting.
Torque both ends of the elbow between 110 - 120
Nm (81 - 89 lb ft).
NOTE: The torque of the nipple in the motor should be
tighten with a torque between 170 - 187 Nm. (125 - 138
lb ft)
NOTE: The case drain line may have sprung. Use a
crowbar or other prying device to line the pipe up enough
to engage the threads of the fitting to prevent galling.
ZDA7552A_45 3
5. Lubricate and install O-rings into the ends of the

main high pressure lines (3).
IMPORTANT: Be sure that the high pressure line of port
"A" from the hydrostatic pump is connected with the high
pressure line of port "B" from the hydrostatic motor. (Port
“A" pump = Port “B" motor)
6. Attach the high pressure lines to the motor, using
four cap screws for each fitting. Tighten the cap
screws to a torque between 104 - 114 Nm (77 - 84
lb ft).
12131 1 02/07/2004
C.20.F / 46
7. Prepare the system for operation in accordance

with “Filling The Hydrostatic System and Start-Up
Procedure". Refer to TRANSMISSION Hydrostatic
- Filling (C.20.F - F.60.A.10) and TRANSMISSION
Hydrostatic - Start up (C.20.F - F.35.A.41).
8. Install the gearbox cover plate.
12131 1 02/07/2004
C.20.F / 47
TRANSMISSION Hydrostatic - Troubleshooting (C.20.F - G.40.A.10)

CS540, CS640, CS520, CS660

Machine will not operate Control cable not connected Connect control cable
in either direction
Low hydrostatic oil Check and fill the reservoir to the correct
oil level. Use specified oil only.
Air in system Locate and repair leak
Exceeding relief valve pressure Shift to lower gear
Drive system unable to build up pressure Air in system. Air will also cause the
system to be noisy. Check all fittings,
especially around the filter, in the suction
line and locate the point or points where
air is being drawn into the system. Tighten
fittings and joints where air leaks exist.
Replace seal where necessary.
Charge pressure relief valve is stuck open Repair charge pressure relief valve.
Combine does not move Transmission gear selector in neutral Select required gear
when hydrostatic control
lever is moved.
Selected transmission gear too high Change to lower gear
to move combine activating pressure
override
Reservoir oil level very low Check and fill the reservoir to the correct
oil level. Used specified oil only
Air in system (may be due to low oil level) Purge air from system.
Hydrostatic lines leaking Check, tighten or replace as necessary
Blocked hydrostatic filter Check and replace filter element as
necessary
Hard to select a Hydrostatic pump not in neutral though Readjust control cable
transmission gear, or hydrostatic control lever is in neutral
will not go into gear
Neutral is difficult or Hydrostatic lever out of calibration Readjust control cable
impossible to find
Ground travel speed Oil level low Check for leaks and repair as necessary
erratic
Blocked oil filter element Change filter element
Exceeding relief valve pressure Shift to lower gear. Repair or replace relief
valve.
Unable to maintain charge pressure The charge pressure relief valve is
damaged or stuck open. Internal damage
to pump or motor
Cold or low oil supply Check oil levels. Allow oil to warm.
Ground speed or combine Reservoir oil level low Check and fill the reservoir to the correct
erratic and loses power. oil level. Used specified oil only.
Also seems to lack power
Hydraulic lines leaking Check level, fill as necessary
necessary
Internal leaks or malfunction in pump or Pressure test system, repair or replace
motor motor or pump as required.
Oil temperature too high Low oil level Fill to correct level and check for leaks
Blocked oil cooler Clean / replace as required
Blocked inlet filter Replace filter
System pressure too high, relief valve Pressure test system, inspect multi
continually blowing function valves
12131 1 02/07/2004
C.20.F / 48

System noisy Air in system Check and fill the reservoir to the correct
oil level. Use specified oil only
Suction line between reservoir and charge Repair leaks
pump, including suction filter, leaking and
allowing air to be drawn into the system,
indicated by considerable amount of foam
in the reservoir
End of return line within the reservoir not Check and fill the reservoir to the correct
below the oil level oil level. Used specified oil only
Hose or tubing not properly insulated Make sure all hoses and tubes are
correctly routed and secured. Make sure
the hoses and tubes are clear of any metal
that will act as a sound board for normal
hydraulic hum. Insulate hose and tube
clamps with rubber to absorb sound.
Acceleration and Filter or suction line from reservoir to Replace filter element and check and
deceleration sluggish charge pump is blocked remove obstructions from suction line
Control orifice plug is partially blocked Inspect and clean / replace as required
necessary
.Air in system Check fittings for air leaks.
Repair as necessary
Low charge pressure Inspect filter and hoses.
Inspect charge pump relief valve.
Inspect the charge pump
Unit surges .Air in system .Check fittings for air leaks between
reservoir and charge pump.
Repair as necessary.
.Low hydrostatic oil .Check and fill the reservoir to the correct
oil level. Used specified oil only.
.Blocked hydrostatic filter .Check and replace filter element as
necessary
.Exceeding relief valve pressure .Shift to lower gear
.Unable to maintain charge pressure .Repair or replace charge pressure relief
valve
.System contaminated .Flush system
.Faulty pump .Repair or replace pump
12131 1 02/07/2004
C.20.F / 49
Index
POWER TRAIN - C
Control valve - Static description (C.20.F.13 - C.30.A.20) 15

CS540, CS640, CS520, CS660
Motor - Component identification (C.20.F.28 - C.40.C.20) 23
CS540, CS640, CS520, CS660
CS520
CS540, CS640
CS660
Motor - Install (C.20.F.28 - F.10.A.15) 46
CS540, CS640, CS520, CS660
Motor - Remove (C.20.F.28 - F.10.A.10) 44
CS540, CS640, CS520, CS660
Motor - Static description (C.20.F.28 - C.30.A.20) 22
CS540, CS640, CS520, CS660
Oil cooler by-pass - General specification (C.20.F.19 - D.40.A.10) 4
CS540, CS640, CS520, CS660
Pump - Component identification (C.20.F.20 - C.40.C.20) 21
CS540, CS640, CS520, CS660
CS520
CS540, CS640
CS660
Pump - Install (C.20.F.20 - F.10.A.15) 41
CS540, CS640, CS520, CS660
Pump - Remove (C.20.F.20 - F.10.A.10) 39
CS540, CS640, CS520, CS660
Pump - Static description (C.20.F.20 - C.30.A.20) 20
CS540, CS640, CS520, CS660
Relief valve - Replace (C.20.F.16 - F.10.A.30) 38
CS540, CS640, CS520, CS660
Relief valve - Static description (C.20.F.16 - C.30.A.20) 18
CS540, CS640, CS520, CS660
Shuttle spool valve - Install (C.20.F.14 - F.10.A.15) 37
CS540, CS640, CS520, CS660
Shuttle spool valve - Remove (C.20.F.14 - F.10.A.10) 36
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Dynamic description (C.20.F - C.30.A.10) 12
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Filling (C.20.F - F.60.A.10) 26
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Hydrostatic schema (C.20.F - C.20.B.25) 7
CS540, CS640, CS520, CS660
12131 1 02/07/2004
C.20.F / 50
TRANSMISSION Hydrostatic - Hydrostatic symbol (C.20.F - C.20.C.25) 9
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Pressure test (C.20.F - F.40.C.30) 32
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Service instruction (C.20.F - F.10.A.05) 24
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Special tools (C.20.F - D.20.A.40) 4
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Start up (C.20.F - F.35.A.41) 30
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Static description (C.20.F - C.30.A.20) 10
CS540, CS640, CS520, CS660
TRANSMISSION Hydrostatic - Troubleshooting (C.20.F - G.40.A.10) 48
CS540, CS640, CS520, CS660
12131 1 02/07/2004
C.20.F / 51
12131 1 02/07/2004
C.20.F / 52
POWER TRAIN - C
PROCESS DRIVE Primary process drive - 50.B
CS540
CS640
CS520
CS660
12132 1 02/07/2004
C.50.B / 1
Contents
POWER TRAIN - C
TECHNICAL DATA
PROCESS DRIVE Primary process drive - Special tools (C.50.B - D.20.A.40) 4

CS540, CS640, CS520, CS660
FUNCTIONAL DATA
Intermediate shaft
Intermediate shaft - Exploded view (C.50.B.43 - C.10.A.20) 5
CS540, CS640, CS520, CS660
Intermediate shaft Right hand bearing - Sectional view (C.50.B.43.01 - C.10.A.30) 6
CS540, CS640, CS520, CS660
Intermediate shaft Left hand bearing - Sectional view (C.50.B.43.02 - C.10.A.30) 7
CS540, CS640, CS520, CS660
Clutch
Clutch - Sectional view (C.50.B.46 - C.10.A.30) 8
CS540, CS640, CS520, CS660
Clutch - Exploded view (C.50.B.46 - C.10.A.20) 9
CS540, CS640, CS520, CS660
SERVICE
Intermediate shaft
Intermediate shaft Right hand bearing - Remove (C.50.B.43.01 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Intermediate shaft Right hand bearing - Install (C.50.B.43.01 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Intermediate shaft Left hand bearing - Remove (C.50.B.43.02 - F.10.A.10) 13
CS540, CS640, CS520, CS660
Intermediate shaft Left hand bearing - Install (C.50.B.43.02 - F.10.A.15) 16
CS540, CS640, CS520, CS660
Intermediate shaft - Remove (C.50.B.43 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Intermediate shaft - Install (C.50.B.43 - F.10.A.15) 20
CS540, CS640, CS520, CS660
Clutch
Clutch - Remove (C.50.B.46 - F.10.A.10) 21
CS540, CS640, CS520, CS660
Clutch - Disassemble (C.50.B.46 - F.10.A.25) 23
CS540, CS640, CS520, CS660
Clutch - Assemble (C.50.B.46 - F.10.A.20) 26
CS540, CS640, CS520, CS660
12132 1 02/07/2004
C.50.B / 2
Clutch - Install (C.50.B.46 - F.10.A.15) 29
CS540, CS640, CS520, CS660
Rotary union
Rotary union - Test (C.50.B.47 - F.40.C.01) 34
CS540, CS640, CS520, CS660
12132 1 02/07/2004
C.50.B / 3
POWER TRAIN - PROCESS DRIVE Primary process drive
PROCESS DRIVE Primary process drive - Special tools (C.50.B -

D.20.A.40)
CS540, CS640, CS520, CS660

Puller 380000320
ZEIL04CS0101A0B 1
12132 1 02/07/2004
C.50.B / 4
Intermediate shaft - Exploded view (C.50.B.43 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7345A 1
Intermediate shaft
1 Intermediate shaft 2 Ring

3 Right-hand side bearing housing 4 Right-hand side bearing
5 Ring 6 Bolt
7 Left-hand side bearing 8 Left-hand side bearing housing
9 Ring 10 Ring
11 Retaining ring 12 Ring
13 Bolt 14 Grease line
12132 1 02/07/2004
C.50.B / 5
Intermediate shaft Right hand bearing - Sectional view (C.50.B.43.01

- C.10.A.30)
CS540, CS640, CS520, CS660
ZDA7342A 1
Right-hand bearing
1 Intermediate shaft 2 Key

3 Retaining ring 4 Pulley
5 Key 6 Ring
7 Bearing 8 Bearing housing
9 Ring
12132 1 02/07/2004
C.50.B / 6
Intermediate shaft Left hand bearing - Sectional view (C.50.B.43.02

- C.10.A.30)
CS540, CS640, CS520, CS660
ZDA7343A 1
Left-hand bearing
1 Ring 2 Intermediate shaft

3 Bearing 4 Ring
5 Bearing housing 6 Retaining ring
7 Ring
12132 1 02/07/2004
C.50.B / 7
Clutch - Sectional view (C.50.B.46 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDA7602A 1
Pneumatic clutch threshing
1 Hose clamp 2 Air hose

3 Air hose 4 Nut
5 Rotary union 6 Nut
7 Nut 8 Jam nut
9 Nut 10 Bolt
11 Washer 12 Bolt
13 Clutch 14 Key
15 Pulley 16 Disc
17 Bolt
12132 1 02/07/2004
C.50.B / 8
Clutch - Exploded view (C.50.B.46 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7638A 1
Pneumatic clutch threshing
1 Bolt 2 Bolt
3 Plate 4 Tyre
5 Disc 6 Support
7 Bushing 8 Disc
9 Sheave 10 Pulley
11 Plate 12 Plate
13 Roll pin 14 Spring
12132 1 02/07/2004
C.50.B / 9
Intermediate shaft Right hand bearing - Remove (C.50.B.43.01 -

F.10.A.10)
CS540, CS640, CS520, CS660
Prior operation: Remove first the cleaning fan variator drive belt, the cleaning shoe drive belt and the rotary
separator drive belt. Refer to Drive system Belt - Remove (K.42.C.40.44 - F.10.A.10).
1. Remove the inner sheave (1), using a puller.
ZDA7482A 1
2. Remove the key (2)

Remove the retaining ring (3).
Remove the pulley (4), if necessary using a puller.
ZDA7338A 2
3. Remove the key (5).

Remove the three bolts (7).
Install three threaded rods instead of the bolts (7)
to pull of the bearing housing (8) together with the
ring (6), using the special tool. PROCESS DRIVE
Primary process drive - Special tools (C.50.B
- D.20.A.40).
ZDA7339A 3
12132 1 02/07/2004
C.50.B / 10
Intermediate shaft Right hand bearing - Install (C.50.B.43.01 -

F.10.A.15)
CS540, CS640, CS520, CS660
NOTE: Refer also to Intermediate shaft Right hand bearing - Sectional view (C.50.B.43.01 - C.10.A.30)
1. Install the ring (9) onto the shaft, using a tube.
ZDA7340A 1
2. Install the bearing housing (8) with the bearing

installed onto the intermediate shaft, using a tube.
ZDA7341A 2
3. Install and tighten the bolts (7).

Heat-up the ring (6) to install.
Install the key (5).
ZDA7339A_28 3
12132 1 02/07/2004
C.50.B / 11

Install the retaining ring (3).
ZDA7338A 4
5. Install the inner sheave (1).
ZDA7482A 5
Next operation: Install first the rotary separator drive belt, the cleaning shoe drive belt and the cleaning fan variator
drive belt. Refer to Drive system Belt - Install (K.42.C.40.44 - F.10.A.15).
12132 1 02/07/2004
C.50.B / 12
Intermediate shaft Left hand bearing - Remove (C.50.B.43.02 -

F.10.A.10)
CS540, CS640, CS520, CS660
Prior operation: Remove first the drum variator drive disks. Refer to Speed regulation system - Remove
(K.40.B.42.50 - F.10.A.10) .
1. Disconnect the wires (1) of the electric motor.
ZDA7522A 1
2. Remove the bolts (1) and remove the support (2)

with the electric motor (3).
ZDA7353A 2
3. Remove the ring (1) and the bushing (2).
ZDA7523A 3
12132 1 02/07/2004
C.50.B / 13
4. Screw out the threaded rod (3).
ZDA7332A 4
5. Remove the bolt (4) and the bushing on both sides

to remove the bearing housing (5).
ZDA7333A 5
6. Remove the bolt (6) on both sides to remove the

arm (7).
ZDA7334A 6
7. Remove the dowel pin (1) on both sides to remove

the arms (2).
Remove the grease line (3) completely.
ZDA7335A 7
12132 1 02/07/2004
C.50.B / 14
8. Remove the three bolts (4).
ZDA7337A 8
9. Install three threaded rods to pull of the bearing

housing (5), using the special tool. Refer to
PROCESS DRIVE Primary process drive -
Special tools (C.50.B - D.20.A.40).
ZDA7336A 9
12132 1 02/07/2004
C.50.B / 15
Intermediate shaft Left hand bearing - Install (C.50.B.43.02 -

F.10.A.15)
CS540, CS640, CS520, CS660
1. Install the ring (1). Refer to Intermediate shaft

Left hand bearing - Sectional view (C.50.B.43.02
- C.10.A.30).
2. Install the bearing housing (5) with the bearing
installed on the intermediate shaft, using a tube.
ZDA7336A 1
3. Install and tighten the three bolts (4).

Install the ring (7).
ZDA7337B 2
4. Install the grease line (3).

Install the two arms (2) and secure it with the dowel
pins (1).
ZDA7335A_24 3
12132 1 02/07/2004
C.50.B / 16
5. Install the arm assembly (7) with the two bolts (6).
Add Loctite 242 on the two bolts (6). (Omnifit 50M,
Permabond 113)
NOTE: The arms must turn freely.
ZDA7334A_25 4
6. Install the bearing housing (5) with the bushings

and install the two bolts (4) foreseen with Loctite
242. (Omnifit 50M, Permabond 113)
NOTE: The arms must turn freely.
ZDA7333A 5
7. Screw in the threaded rod (3) completely.

IMPORTANT: Adjust the bracket (2) with dimension “X"
between 193 - 195 mm. (7-19/32 - 7-11/16 in)
ZDA7332B 6
8. Install the bushing (2) and the ring (1) with the
plastic side on the moving side.
ZDA7523A_26 7
12132 1 02/07/2004
C.50.B / 17
9. Move the support (2) with the electric motor (3) as

fare as possible forward and tighten the bolts (1).
ZDA7353A_27 8
Next operation: Install the drum variator drive disks. Refer to Drum variator Drive disc - Install (K.40.B.43.50 -
F.10.A.15).
Next operation: Adjust the drum variator belt, if necessary. Refer to Speed regulation system - Adjust
(K.40.B.42 - F.45.A.01).
12132 1 02/07/2004
C.50.B / 18
Intermediate shaft - Remove (C.50.B.43 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: At the left-hand side:

Remove the drum variator drive disks. Refer to Drum variator Drive disc - Remove (K.40.B.43.50 - F.10.A.10).
Prior operation: Remove the left-hand-side bearing. Refer to Intermediate shaft Left hand bearing - Remove
(C.50.B.43.02 - F.10.A.10).
Prior operation: At the right-hand side:
Remove the fan variator driven disks. Refer to Fan variator Driven disc - Remove (K.62.B.53.51 - F.10.A.10).
Prior operation: Remove the right-hand-side bearing. Refer to Intermediate shaft Right hand bearing - Remove
(C.50.B.43.01 - F.10.A.10).
1. Take out the intermediate shaft (1).
ZDA7344A 1
12132 1 02/07/2004
C.50.B / 19
Intermediate shaft - Install (C.50.B.43 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Insert the intermediate shaft (1) in the frame.
ZDA7344A 1
Next operation: Install the right-hand side bearing. Refer to Intermediate shaft Right hand bearing - Install
(C.50.B.43.01 - F.10.A.15).
Next operation: Install the left-hand side bearing. Refer to Intermediate shaft Left hand bearing - Install
(C.50.B.43.02 - F.10.A.15).
Next operation: Install the drum variator drive disks. Refer to Drum variator Drive disc - Install (K.40.B.43.50 -
F.10.A.15).
Next operation: Install the fan variator driven disks. Refer to Fan variator Driven disc - Install (K.62.B.53.51 -
F.10.A.15).
12132 1 02/07/2004
C.50.B / 20
Clutch - Remove (C.50.B.46 - F.10.A.10)

CS540, CS640, CS520, CS660
CAUTION
1. Loosen the hose clamp (1) to disconnect the air

hose (2) from the rotary union.
ZDA7084B 1
2. To disconnect the air hoses (3), push onto the ring

(arrow) after pull the air hose out of the connector.
ZEIL04CS0075A0B 2
3. Loosen the nut (4).

Remove the rotary union (5) by turning the nut (6)
counter-clockwise.
ZDA7600A_75 3
12132 1 02/07/2004
C.50.B / 21
4. Loosen the four nuts (7) and remove the bolts.

Loosen the jam nut (8) and the nut (9).
Remove the four bolts (10).
ZDA7596A 4
5. Remove the washer (11).

Remove the two bolts (12) and install two threaded
rods to remove the clutch. (see next item)
ZDA7597A 5
6. Remove the pneumatic clutch (13) completely by

using a special puller. Be careful, the clutch is
heavy.
ZDA7598A 6

To remove the pulley (15), using a puller.
ZDA7599A 7
12132 1 02/07/2004
C.50.B / 22
Clutch - Disassemble (C.50.B.46 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Remove the clutch, refer to Clutch - Remove

(C.50.B.46 - F.10.A.10).
IMPORTANT: Before to start disassemble the clutch,
mark all the parts.
2. Remove the bolts (1).
Lift-up and turn the sheave (2) with the clutch.
ZDA7608A 1
3. Remove the four springs (3).
ZDA7612A 2
4. Remove the four Allen screws (4) and remove the

sheave from the clutch.
ZDA7609A 3
12132 1 02/07/2004
C.50.B / 23
5. Now is it possible to remove the disc (5).
ZDA7610A 4
6. If necessary, remove the bushing (6).
ZDA7613A 5
7. To remove the tyre from the sheave, remove the

two nuts (1) of the air connections.
ZDA7614A 6
8. Now is it possible to remove the tyre (2) out of the

sheave.
ZDA7615A 7
12132 1 02/07/2004
C.50.B / 24
9. To check, remove the disc (3).
ZDA7611A 8
12132 1 02/07/2004
C.50.B / 25
Clutch - Assemble (C.50.B.46 - F.10.A.20)

CS540, CS640, CS520, CS660
Before assemble the clutch, clean all the parts with compressed air.
1. Install the tyre (2) in the sheave.
ZDA7615A 1
2. Install the air connections with, using Loctite 542

(Omnifit 80M, Permabond 130 )
Tighten the two nuts (1).
ZDA7614A 2
3. Replace the bushing (6), if necessary.
ZDA7613A 3
12132 1 02/07/2004
C.50.B / 26
4. Place the disc (5) onto his place.
ZDA7610A 4
5. Install the sheave with the tyre installed onto the

disc (5) (fig.2).
Install and tighten the four Allen screws (4).
ZDA7609A 5
6. Install the four springs (3).
ZDA7612A 6
7. install the disc (3) onto the sheave (4).
ZDA7611A 7
12132 1 02/07/2004
C.50.B / 27
8. Install the pre-assembled sheave (2) onto the

sheave (4) (fig.7).
Install and tighten the four bolts (1).
ZDA7714A 8
12132 1 02/07/2004
C.50.B / 28
Clutch - Install (C.50.B.46 - F.10.A.15)

CS540, CS640, CS520, CS660
CAUTION
1. Install the pulley (15) onto the shaft.

ZDA7599A 1
2. Install the pre-assembled clutch (13). Be careful,

the clutch is heavy.
ZDA7601A 2
3. Install and tighten the four bolts (10).

Install and tighten the two bolts (12).
ZDA7673A 3
12132 1 02/07/2004
C.50.B / 29
4. Install and tighten the nut (9) with a torque between

630 - 650 Nm. (465 - 479 lb ft)
Install and tighten the jam nut (8) with a torque
between 480 - 500 Nm. (354 - 369 lb ft)
ZDA7596B 4
5. Install the bolts (17) and tighten the nuts (7). (Refer
to Clutch - Sectional view (C.50.B.46 - C.10.A.30))
NOTE: Check when installing the four bolts (17) if
dimension “X" is between 23 - 30 mm. (29/32 - 1-3/16 in)
ZDA7670A 5
12132 1 02/07/2004
C.50.B / 30
6. Before install the rotary union (5), add Loctite 242

(OMNIFIT 50M or PERMABOND 113) onto the
thread end.
Install the rotary union (5) by turning the nut (6)
clockwise.
Tighten the nut (4) with a torque between 27 - 32
Nm. (20 - 24 lb ft)
ZDA7600A_75 6
7. Connect the air hoses (3) onto the clutch.

Install the air hose (2) onto the rotary union and
tighten the hose clamp (1).
ZDA7084B_76 7
8. Start the engine and engage the threshing

mechanism.
9. After 15 seconds disengage the threshing
mechanism and stop the engine.
CAUTION
Z009 - Before starting a service job, always:-Shut off
the engine-Remove the ignition key-Switch off the
battery switch-Wait until all parts have completely
stopped rotating
12132 1 02/07/2004
C.50.B / 31
10. Check now if the minimum distance "Y" and "Z" on

both sides of the disc (16) = 0.5 mm (0.020 in).
ZDA7670B 8
11. If not, remove the bolts (2) or (4) and add or remove
the shims (1).
After adjusting, install the bolts (2) and (4), apply
Loctite 270 (OMNIFIT 200M or PERMABOND 118)
onto the thread of the bolt (2).
NOTE: Change the nut (3), after two replaces.
ZDF00826A 9
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C.50.B / 32
12. Check that the plates (5) are installed as shown.

"X" = 90 ° degrees.
ZDF0824A 10
13. The four bolts (2) are provided with the pneumatic
clutch, when there is missing pressure, which permit
blocking the clutch in case of damage to the clutch.
ZDA7084C 11
14. To block the clutch, proceed as follows:

1. Loosen the four nuts (1).
2. Tighten the bolts (2) to a torque of 91 Nm
(67 lb ft).
3. Retighten the nuts (1).
CAUTION
Z004 - Be aware that in this case the threshing
mechanism is running directly when starting the
engine if the threshing clutch is blocked as explained
above.
12132 1 02/07/2004
C.50.B / 33
Rotary union - Test (C.50.B.47 - F.40.C.01)

CS540, CS640, CS520, CS660
To test the rotary union for leaks, proceed as follows:
1. Remove the rotary union (20), refer to Clutch -

Remove (C.50.B.46 - F.10.A.10).
ZDF0846A 1
2. Connect the port (1) onto filtrate and lubricated

compressed air with a pressure between 6 - 10 bar.
3. Close the ports (2).
4. Dip the union in a bath with engine oil and check
if there is no leak during minimum 5 seconds.
ambient temperature +/- 20 ° C (68 °F)
12132 1 02/07/2004
C.50.B / 34
Index
POWER TRAIN - C
Clutch - Assemble (C.50.B.46 - F.10.A.20) 26

CS540, CS640, CS520, CS660
Clutch - Disassemble (C.50.B.46 - F.10.A.25) 23
CS540, CS640, CS520, CS660
Clutch - Exploded view (C.50.B.46 - C.10.A.20) 9
CS540, CS640, CS520, CS660
Clutch - Install (C.50.B.46 - F.10.A.15) 29
CS540, CS640, CS520, CS660
Clutch - Remove (C.50.B.46 - F.10.A.10) 21
CS540, CS640, CS520, CS660
Clutch - Sectional view (C.50.B.46 - C.10.A.30) 8
CS540, CS640, CS520, CS660
Intermediate shaft - Exploded view (C.50.B.43 - C.10.A.20) 5
CS540, CS640, CS520, CS660
Intermediate shaft - Install (C.50.B.43 - F.10.A.15) 20
CS540, CS640, CS520, CS660
Intermediate shaft - Remove (C.50.B.43 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Intermediate shaft Left hand bearing - Install (C.50.B.43.02 - F.10.A.15) 16
CS540, CS640, CS520, CS660
Intermediate shaft Left hand bearing - Remove (C.50.B.43.02 - F.10.A.10) 13
CS540, CS640, CS520, CS660
Intermediate shaft Left hand bearing - Sectional view (C.50.B.43.02 - C.10.A.30) 7
CS540, CS640, CS520, CS660
Intermediate shaft Right hand bearing - Install (C.50.B.43.01 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Intermediate shaft Right hand bearing - Remove (C.50.B.43.01 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Intermediate shaft Right hand bearing - Sectional view (C.50.B.43.01 - C.10.A.30) 6
CS540, CS640, CS520, CS660
PROCESS DRIVE Primary process drive - Special tools (C.50.B - D.20.A.40) 4
CS540, CS640, CS520, CS660
Rotary union - Test (C.50.B.47 - F.40.C.01) 34
CS540, CS640, CS520, CS660
12132 1 02/07/2004
C.50.B / 35
PRINTED IN BELGIUM
12129 1 02/07/2004
REPAIR MANUAL
TRAVELLING
CS540
CS640
CS520
CS660
12133 1 02/07/2004
D
Contents
TRAVELLING - D
FRONT AXLE D.10.A

CS540, CS640, CS520, CS660
REAR AXLE D.12.A

CS540, CS640, CS520, CS660
2WD-4WD SYSTEM Hydrostatic D.14.E

CS540, CS640, CS660
STEERING Hydraulic D.20.C

CS540, CS640, CS520, CS660
STEERING Mechanical D.20.B

CS540, CS640, CS520, CS660
SERVICE BRAKE Hydraulic D.30.C

CS540, CS640, CS520, CS660
PARKING BRAKE Mechanical D.32.B

CS540, CS640, CS520, CS660
12133 1 02/07/2004
D
TRAVELLING - D
FRONT AXLE - 10.A
CS540
CS640
CS520
CS660
12134 1 02/07/2004
D.10.A / 1
Contents
TRAVELLING - D
FRONT AXLE - 10.A
TECHNICAL DATA
Final drive
Final drive - Torque (D.10.A.42 - D.20.A.10) 4
CS520
CS540, CS640
CS660
Final drive - Special tools (D.10.A.42 - D.20.A.40) 4
CS540, CS640
Final drive - General specification (D.10.A.42 - D.40.A.10) 5
CS540, CS640, CS520
CS660
FUNCTIONAL DATA
Final drive
Final drive - Sectional view (D.10.A.42 - C.10.A.30) 6
CS520
CS540, CS640
CS660
Final drive - Exploded view (D.10.A.42 - C.10.A.20) 10
CS540, CS640
CS660
Final drive - Overview (D.10.A.42 - C.10.A.10) 14
CS520
CS540, CS640
CS660
SERVICE
Final drive
Final drive - Remove (D.10.A.42 - F.10.A.10) 18
CS540, CS640, CS520, CS660
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D.10.A / 2
Final drive - Disassemble (D.10.A.42 - F.10.A.25) 20
CS520
Final drive - Assemble (D.10.A.42 - F.10.A.20) 21
CS520
CS540, CS640
CS540, CS640
CS660
CS660
Final drive - Install (D.10.A.42 - F.10.A.15) 32
CS540, CS640, CS520, CS660
Final drive Wheel stud - Replace (D.10.A.42.60 - F.10.A.30) 33
CS540, CS640, CS520, CS660
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D.10.A / 3
TRAVELLING - FRONT AXLE
Final drive - Torque (D.10.A.42 - D.20.A.10)

CS520
10/75 final drive

Bolt final drive cover 28-45 Nm ( 21-33 lb ft)
Bolt input shaft cover 34 Nm (25 lb ft)
Bolt in output shaft 235 Nm (175 lb ft)
Level plug 70-90 Nm (50-65 lb ft)
Magnetic plug 90-110 Nm (65-80 lb ft)
Filler / Breather plug 90-110 Nm (65-80 lb ft)
Bolt final drive to traction beam 670 Nm (494 lb ft)
Wheel nuts torque 610-732 Nm (450 - 540 lb ft)

CS540, CS640
10/75 final drive


CS660
11/111 final drive

Final drive - Special tools (D.10.A.42 - D.20.A.40)

CS540, CS640

10/75 Final drive axle ring nut wrench
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D.10.A / 4
Final drive - General specification (D.10.A.42 - D.40.A.10)

CS540, CS640, CS520
10/75 final drive

Gear ratio 10/75
Max. input rpm (30 km/h - 18.6 miles/h) 1000 rpm
Max. output rpm (30 km/h - 18.6 miles/h) 100 rpm
Nom. input torque 1645 Nm (1213 lb ft)
Nom. output torque 12400 Nm (9146 lb ft)
Input shaft axial end play 0.05 - 0.1 mm (0.00197 in - 0.00394 in )
Approx. total weight 180 kg (397 lb)
Oil capacity 5 liters (1.3 US gal)
Final drive - General specification (D.10.A.42 - D.40.A.10)

CS660
11/111 final drive

Gear ratio 11/111
Max. input rpm (30 km/h - 18.6 miles/h) 1000 rpm
Max. output rpm (30 km/h - 18.6 miles/h) 100 rpm
Nom. input torque 1560 Nm (1150 lb ft)
Nom. output torque 15750 Nm (11620 lb ft)
Input shaft axial end play 0.08 - 0.13 mm (0.003 in - 0.005 in )
Approx. total weight 245 kg (540 lb ft)
Oil capacity 7.2 liters (1.9 US gal)
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D.10.A / 5
Final drive - Sectional view (D.10.A.42 - C.10.A.30)

CS520
ZEIL04CS0111G0C 1
10/75 Final drive
1 Seal 2 Bearing
3 Spacer 4 Output gear
5 Cover 6 Retaining ring
7 Seal 8 Bearing
9 Bolts 10 Cover
11 Bolts 12 Washer
13 Wire 14 Seal
15 Shims 16 O-ring
17 Input shaft 18 Output shaft
19 Bearing 20 Bearing
21 Shims
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CS540, CS640
ZDA7858B 1
10/75 Final drive
1 Seal 2 Bearing
7 Seal 8 Bearing
9 Bolts 10 Cover
11 Nut 12 Lock plate
13 Nut 14 Seal
15 Shims 16 O-ring
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D.10.A / 7

CS660
ZEIL04CS0073G0B 1
11/111 Final drive
12134 1 02/07/2004
D.10.A / 8
1 Seal 2 Bearing
5 Cover 6 Spacer
7 Seal 8 Bearing
9 Shims 10 Cover
11 Bolts 12 Washer
13 Seal 14 Bolts
15 Cover 16 Seal
17 O-ring 18 Bearing
19 Input shaft 20 Seal
21 End cap 22 Bolts
23 Output shaft
12134 1 02/07/2004
D.10.A / 9
Final drive - Exploded view (D.10.A.42 - C.10.A.20)

CS540, CS640
ZDA7879A 1
10/75 Final drive
12134 1 02/07/2004
D.10.A / 10
1 Seal 2 Bearing
7 Seal 8 Bearing
9 Bolts 10 Cover
11 Nut 12 Lock plate
13 Nut 14 Seal
15 Shims 16 O-ring
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D.10.A / 11
Final drive - Exploded view (D.10.A.42 - C.10.A.20)

CS660
ZEIL04CS0087H0B 1
11/111 Final drive
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D.10.A / 12
1 Seal 2 Bearing
5 Cover 6 Spacer
7 Seal 8 Bearing
9 Shims 10 Cover
11 Bolts 12 Washer
13 Seal 14 Bolts
15 Cover 16 Seal
17 O-ring 18 Bearing
19 Input shaft 20 Seal
21 End cap 22 Bolts
23 Output shaft
12134 1 02/07/2004
D.10.A / 13
Final drive - Overview (D.10.A.42 - C.10.A.10)

CS520
ZEIL04CS0111G0B 1
10/75 Final drive
1 Input shaft 2 Output gear

3 Wheel hub
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D.10.A / 14

CS540, CS640
ZDA7858A 1
10/75 Final drive

3 Wheel hub
12134 1 02/07/2004
D.10.A / 15

CS660
ZEIL04CS0073G0C 1
11/111 Final drive
12134 1 02/07/2004
D.10.A / 16

3 Wheel hub
12134 1 02/07/2004
D.10.A / 17
Final drive - Remove (D.10.A.42 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the traction tyre from the combine.
CAUTION
Z016 - Install a suitable and safe support underneath
the combine traction axle to support the combine.
2. Loosen the nut (5) and remove the bolt.
ZEIL04CS0030A0B 1
3. Disconnect the sleeve (1) at the final drive.
ZDA7354A_35 2
4. Support the final drive.
CAUTION
Z002 - A final drive is heavy. Take extreme caution
when removing the final drive! Use a supporting
device which can handle this weight!
5. Loosen the bolts (2) and remove the final drive (3).
NOTE: If the final drive needs to be disassembled, drain
the oil before the final drive is removed from the combine
(Refer to the CS Operator’s Manual, SECTION 4 -
“LUBRICATION AND MAINTENANCE").
ZDF0364A 3
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D.10.A / 18
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D.10.A / 19
Final drive - Disassemble (D.10.A.42 - F.10.A.25)

CS520
1. OUTPUT SHAFT:
Refer to Final drive - Sectional view (D.10.A.42
- C.10.A.30).
After draining the oil, remove the covers (5) and
(10).
2. Remove the wire (13) that locks the three bolts (11)
Remove the three bolts, washer (12) and the
shimpac (21).
3. Remove the inner ring of the bearing (8) from the
output shaft (18).
5. Press the wheel hub (18) out of the final drive
housing.
NOTE: The inner ring of the bearing (2) and the spacer
(3) will remain on the shaft. The seal (1) will remain in
the housing.
IMPORTANT: In case mud seals are installed, only a part
of the mud seal will remain on the shaft. The other part will
remain in the housing. The surface between the two parts
of the mud seal should be oiled before touching them.
6. Remove the spacer (3) and the inner ring of the
bearing (2) from the output shaft (18).
7. Remove the output gear (4).
8. Use a soft punch to remove the outer rings of
bearings (8) and (2) out of the final drive housing.
9. If necessary, remove the seal (1) from the final drive
housing.
NOTE: The seal (1) will be damaged when it is removed.
10. INPUT SHAFT:
Remove the bolts (9) and the cover.
NOTE: Shims (15) behind the housing. The seal (14) and
the O-ring (16) will remain in the cover.
11. Remove the input shaft (17) with the bearings (19)
and (20).
12. If necessary, remove the inner rings of the bearings
(19) and (20) from the input shaft.
12134 1 02/07/2004
D.10.A / 20
Final drive - Assemble (D.10.A.42 - F.10.A.20)

CS520
1. INPUT SHAFT:
Install the bearings (19) and (20) on the input
shaft (17). Refer to Final drive - Sectional view
(D.10.A.42 - C.10.A.30).
2. Insert the input shaft (17) assembly into the final
drive housing. (as shown)
NOTE: Fill up the seal (14) with NEW HOLLAND AMBRA
GR 75 MD GREASE.
ZDA7860A 1
3. Install a new O-ring (16). Refer to Final drive -

Sectional view (D.10.A.42 - C.10.A.30).
4. Measure the distance between the final drive
housing and the bearing (19) to determine the
number of shims to be installed to have an end play
between 0.05 - 0.1 mm. Install or remove as much
the shims (15) as necessary to obtain that value.
5. Install and tighten the four bolts (9) of the final drive
housing (13).
ZDA7861A 2
12134 1 02/07/2004
D.10.A / 21
6. OUTPUT SHAFT:
Install the outer rings of bearings (2) and (8) in the
final drive housing.
7. Use NEW HOLLAND AMBRA GR 75 MD GREASE
to lubricate the lip of the seal (1) and to fill the cavity
of the seal.
Install the seal (1) in the final drive housing with the
lip facing to the housing.
8. Heat the inner ring of bearing (2) to 80 °C (176 °F)
and install it on output shaft (23).
9. Coat bearing (2) with oil.
10. Install spacer (3) on the shaft (18).
11. Slide gear (4) into the final drive housing.
12. Bring the output shaft into the final drive housing
through gear (4).
13. Lay the complete final drive housing flat on the
wheel flange.
14. Install the retaining ring (6), outer bearing (8), the
washer (12) and tighten the bolts (11) to 90 Nm (66
lb ft) to make sure bearing (8) is seated correctly.
Loosen the three bolts (11) evenly until there is
some end play on the output shaft. Tap the shaft
with a heavy soft hammer to loosen the bearings
and obtain end play.
15. Install a dial gauge to check the output shaft end
play.
16. Retighten bolts (11) evenly until zero end play is
just reached.
17. Remove the three bolts (11) and the washer (12).
18. Measure the distance between the shaft end and
the outer edge of bearing (8).
19. Install shims (21) for a same value of "X-0.5 mm"
(X-0.02 in).
NOTE: Axial preload on the bearing should be 0.45 - 0.55
mm (0.018 - 0.022 in).
20. Reinstall the washer (12) and tighten the bolts (11)
to 235 Nm (175 lb ft).
21. Secure the bolts (11) with a wire as shown.
NOTE: Wire must be threaded so that, as the hardware
tends to loosen, the wire is stretched tighter. Twist the
ends of the wire for at least 5 twists and position them
against the washer.
ZEIL04CS0110A0B 3
12134 1 02/07/2004
D.10.A / 22
22. Install the cover (10), using Loctite 601 (OMNIFIT

230L, Permabond 148).
ZDA7877A 4
23. Install the cover (5) with a new seal (7) and tighten
the bolts with a torque between 28 - 45 Nm. (21
- 33 lb ft)
24. Fill up the final drive gearbox with 5 liters (1.3
US gal) of oil as described in the CS Operator’s
manual: "SECTION 4 - LUBRICATION AND
MAINTENANCE".
Next operation: Final drive - Install (D.10.A.42 - F.10.A.15)
12134 1 02/07/2004
D.10.A / 23

CS540, CS640
1. Output shaft :
- C.10.A.30) or Final drive - Exploded view
(D.10.A.42 - C.10.A.20)
(10).
2. Remove the nut (11), the lock plate (12) and the
nut (13).
3. Remove the inner ring of the bearing (8) from the
output shaft (18).
housing.
the housing.
bearing (2) from the output shaft (18).
7. Remove the output gear (4).
bearings (8) and (2) out of the final drive housing.
9. If necessary, remove the seal (1) from the final drive
housing.
NOTE: The seal (1) will be damaged when it is removed.
10. Input shaft :
Remove the bolts (9) and the cover (13).
NOTE: Shims (15) behind the housing. The seal (14) and
the O-ring (16) will remain in the cover.
11. Remove the input shaft (17) with the bearings (19)
and (20).
(19) and (20) from the input shaft.
12134 1 02/07/2004
D.10.A / 24

CS540, CS640
1. Input shaft :
Install the bearings (19) and (20) on the input
shaft (17). Refer to Final drive - Sectional view
(D.10.A.42 - C.10.A.30).
2. Insert the input shaft (17) assembly into the final
drive housing. (as shown)
NOTE: Fill up the seal (14) with grease NLGI-2.
ZDA7860A 1
3. Install a new O-ring (16). (Refer to Final drive -

Sectional view (D.10.A.42 - C.10.A.30))
4. Measure the distance between the final drive
housing and the bearing (19) to determine the
number of shims to be installed to have an end play
between 0.05 - 0.1 mm. Install or remove as much
the shims (15) as necessary to obtain that value.
5. Install and tighten the four bolts (9) of the final drive
housing (13).
ZDA7861A 2
12134 1 02/07/2004
D.10.A / 25
6. Output shaft :
Install the both outer rings of the bearings (2) and
(8) in the final drive housing.
Install the seal (1) as shown and apply grease to
the lip of the seal.
ZDA7861B 3
7. Install the inner ring of the bearing (2) and the

spacer (3) on the output shaft (18).
ZDA7862A 4
8. Slide the output gear (4) into the final drive housing.
Bring the output shaft assembly into the final drive
housing, through the output gear.
ZDA7863A 5
9. Install the retaining ring (6) (Refer to Final drive -

Sectional view (D.10.A.42 - C.10.A.30)) and the
bearing (8).
Install the first nut (13) and tighten it to a torque of
250 Nm. (184.4 lb ft), using the final drive axle ring
nut wrench, refer to Final drive - Special tools
(D.10.A.42 - D.20.A.40)
Rotate the output shaft (18) three to four times in
the housing.
Repeat the last two sequences until the nut (13)
does not turn when tightening to a torque of 250
Nm. (184.4 lb ft)
Loosen the nut (13) and retighten until there is no
free play (20 - 40 Nm) (14.8 - 29.5 lb ft) +72 °
6
further, to give preload. ZDA7864A
12134 1 02/07/2004
D.10.A / 26
10. Install the lock plate (12) and the second nut (11)
and tighten it to a torque between 1950 - 2050 Nm
(1438 - 1512 lb ft), while holding the first nut in the
same position.
Bend the lips of the lock plate (12) to secure the
nuts (11) and (13).
ZDA7865A 7
11. Install the cover (10), using Loctite 601 (OMNIFIT

230 L, Permabond 148).
ZDA7877A 8
12. Install the cover (5) with a new seal (7) and tighten
the bolts with a torque between 28 - 45 Nm. (21
- 33 lb ft)
13. Fill up the final drive gearbox with 5 liters (1.3
US gal) of oil as described in the CS Operator’s
manual: “SECTION 4 - LUBRICATION AND
MAINTENANCE".
12134 1 02/07/2004
D.10.A / 27

CS660
1. OUTPUT SHAFT :
(D.10.A.42 - C.10.A.20)
(10).
2. Remove the wire that locks three bolts (11).
Remove the three bolts, washer (12) and the
shimpac (9).
housing.
the housing.
bearing (2) from the output shaft.
NOTE: Bearing (2) will be damaged when it is removed.
5. Remove the output gear (4), spacer (6) and the inner
ring of bearing (8) out of the final drive housing.
6. If necessary, remove seal (1) from the final drive
housing.
NOTE: Seal (1) will be damaged when it is removed.
bearings (2) and (8) from the final drive housing.
8. INPUT SHAFT:
Remove the bolts (22) and the cover (21) with seal
(20).
9. Remove the bolts (14) and (15).
NOTE: The seal (16) and the O-ring (17) will remain in
the cover.
10. Remove the input shaft (19) by striking on the shaft
on the splined end with a soft hammer.
11. Use a soft punch to remove the inner rings of
bearing (18) from the input shaft.
(18) from the input shaft.
12134 1 02/07/2004
D.10.A / 28

CS660
1. INPUT SHAFT:
(D.10.A.42 - C.10.A.20)
2. Heat the inner rings of bearings (18) to 80 °C (176
°F) and install them on the input shaft (19).
3. Insert the input shaft assembly into the final drive
housing.
4. Install both outer rings of bearings (18).
5. Install end cap (21) with a new seal (20).
6. Apply Loctite 242 to bolts (22) and tighten them.
7. Install a new seal (16) and O-ring (17) in the cover
(15) and apply grease to the lip of seal (16).
8. Slide cover (15) over the input shaft.
NOTE: Making sure not to damage the lip of the seal (16).
9. Tighten the bolts (14) up to 34 Nm (25 lb ft)
10. Check the end play on the input shaft (19). It should
be between 0.08 - 0.13 mm (0.0032 - 0.0051 in).
Install or remove as much shims (13) as necessary
to obtain that value.
NOTE: Install shims (13) behind the cover (15).
11. After checking the end play, remove the cover (15)
and shims (13) again and apply sealing compound
between the cover and the first shims, between the
shims and between the last shim and the final drive
housing to create a complete seal.
12. Reinstall cover (15) with shims (13).
13. Apply Loctite 242 to the bolts (14) and tighten them
to 34 Nm (25 lb ft).
12134 1 02/07/2004
D.10.A / 29
14. OUTPUT SHAFT:

Install the outer rings of bearings (2) and (8) in the
final drive housing.
15. Use NEW HOLLAND AMBRA GR 75 MD GREASE
to lubricate the lip of the seal (1) and to fill the cavity
of the seal.
Install the seal (1) in the final drive housing with the
lip facing to the housing.
Check distance "Y" = 6.5 - 7.5 mm (0.25 - 0.30 in).
NOTE: In case mud seals are installed, install the first
part of the mud seal. Take care that the outer side of the
seal is free of dirt and oil.
16. Heat the inner ring of bearing (2) to 80 °C (176 °F)
and install it on output shaft (23).
NOTE: In case mud seals are installed, install the second
part of the mud seal. Take care that the outer side of the
seal is free of dirt and oil.
17. Coat bearing (2) with oil.
18. Install spacer (3) on shaft (23).
19. Slide gear (4) into the final drive housing.
IMPORTANT: In case mud seals are installed, ensure the
surface between both seals is oiled.
20. Bring the output shaft into the final drive housing
through gear (4).
21. Lay the complete final drive housing flat on the
wheel flange.
22. Install spacer (6), bearing (8), the washer (12) and
tighten the bolts (11) to 90 Nm (66 lb ft) to make
sure bearing (8) is seated correctly. Loosen the
three bolts (11) evenly until there is some end play
on the output shaft. Tap the shaft with a heavy soft
hammer to loosen the bearings and obtain end play.
23. Install a dial gauge to check the output shaft end
play.
24. Retighten bolts (11) evenly until zero end play is
just reached.
25. Remove the three bolts (11) and the washer (12).
26. Measure distance "X" between the shaft end and
the outer edge of bearing (8).
27. Install shims (9) for a same value of "X-0.5 mm"
(X-0.02 in).
NOTE: Axial preload on the bearing should be 0.45 - 0.55
mm (0.018 - 0.022 in).
28. Reinstall washer (12) and tighten the bolts (11) to
235 Nm (175 lb ft).
12134 1 02/07/2004
D.10.A / 30
29. Secure the bolts (11) with a wire as shown.

NOTE: Wire must be threaded so that, as the hardware
tends to loosen, the wire is stretched tighter. Twist the
ends of the wire for at least 5 twists and position them
against the washer.
ZEIL04CS0110A0B 1
30. Install cover (10), using Loctite 638 (OMNIFIT 230H,

PERMABOND 201).
31. Install the cover (5) with a new seal. Apply Loctite
242 (OMNIFIT 50M, PERMABOND 113) to the bolts
and tighten them to 28 - 45 Nm (21 - 33 lb ft).
Next operation: Final drive - Install (D.10.A.42 - F.10.A.15)
12134 1 02/07/2004
D.10.A / 31
Final drive - Install (D.10.A.42 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Insert the two dowel pins (4) in the final drive

housing.
Install the final drive onto the traction axle of the
combine.
CAUTION
Z001 - A final drive is heavy. Take extreme caution
when handling the final drive! Use a supporting
device which can handle this weight!
ZDA7859A 1
2. Apply Loctite 242 (OMNIFIT 50M or PERMABOND

113) to the bolts (2) and install them.
Tighten the bolts (2) to a torque of 440 Nm
(325 lb ft)
ZDF0364A 2
3. Fill the final drive with oil (Refer to the CS Operator’s

Manual, “SECTION 4 - “LUBRICATION AND
MAINTENANCE").
4. Connect the sleeve and install the bolt.
Install a new locknut (5). Tighten the nut so that the
bolt can still be turned freely.
ZEIL04CS0030A0B 3
5. Install the traction wheel and tighten the wheel

nuts to a torque between 610 - 732 Nm
(450 - 540 lb ft).
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D.10.A / 32
Final drive Wheel stud - Replace (D.10.A.42.60 - F.10.A.30)

CS540, CS640, CS520, CS660
1. Remove the traction wheel.
CAUTION
Z016 - Install a suitable and safe support underneath
the combine traction axle to support the combine.
2. Loosen the nut (5) and remove the bolt.
ZEIL04CS0030A0B 1
3. Remove the sleeve (1) at the final drive.
ZDA7354A 2
4. Turn the output shaft of the final drive until wheel

bolt (2) (the bolt to be replaced) is aligned with
notch (3) in the final drive housing.
Drive out the wheel bolt (2).
Insert a new wheel bolt and pull it on its place with a
wheel nut.
NOTE: Make sure that the notch on the wheel bolt is in
line with the step on the output shaft.
ZDA4708A 3
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D.10.A / 33
5. Connect the sleeve (1) and install the bolt.
ZDA7354A 4
6. Install a new locknut (5). Tighten the nut so that the

bolt can still be turned freely.
ZEIL04CS0030A0B 5
7. Install the traction wheel and tighten the wheel

nuts to a torque between 610 - 732 Nm (450 - 540
lb ft).
12134 1 02/07/2004
D.10.A / 34
Index
TRAVELLING - D
FRONT AXLE - 10.A

CS520
CS540, CS640
CS660
CS520
CS540, CS640
CS660
CS540, CS640
CS660
CS540, CS640, CS520
CS660
Final drive - Install (D.10.A.42 - F.10.A.15) 32
CS540, CS640, CS520, CS660
CS520
CS540, CS640
CS660
Final drive - Remove (D.10.A.42 - F.10.A.10) 18
CS540, CS640, CS520, CS660
CS520
CS540, CS640
CS660
Final drive - Special tools (D.10.A.42 - D.20.A.40) 4
CS540, CS640
CS520
CS540, CS640
CS660
Final drive Wheel stud - Replace (D.10.A.42.60 - F.10.A.30) 33
CS540, CS640, CS520, CS660
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D.10.A / 35
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D.10.A / 36
TRAVELLING - D
REAR AXLE - 12.A
CS540
CS640
CS520
CS660
12135 1 02/07/2004
D.12.A / 1
Contents
TRAVELLING - D
REAR AXLE - 12.A
FUNCTIONAL DATA
Hub
Hub - Exploded view (D.12.A.75 - C.10.A.20) 3
CS540, CS640, CS520, CS660
Hub - Sectional view (D.12.A.75 - C.10.A.30) 4
CS540, CS640, CS520, CS660
SERVICE
Hub
Hub - Disassemble (D.12.A.75 - F.10.A.25) 5
CS540, CS640, CS520, CS660
Hub - Assemble (D.12.A.75 - F.10.A.20) 7
CS540, CS640, CS520, CS660
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TRAVELLING - REAR AXLE
Hub - Exploded view (D.12.A.75 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7558A 1
Wheel Bearing
1 Bolt 2 Dust cover

3 Cotter pin 4 Nut
5 Washer 6 Bearing
7 Hub 8 Bearing
9 Seal 10 Plate
11 Spindle 12 Seal
13 Bolt
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D.12.A / 3
Hub - Sectional view (D.12.A.75 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDA7559A 1
Wheel Bearing
1 Bolt 2 Dust cover

3 Cotter pin 4 Nut
5 Washer 6 Bearing
7 Hub 8 Bearing
9 Seal 10 Plate
11 Spindle 12 Seal
13 Bolt
12135 1 02/07/2004
D.12.A / 4
Hub - Disassemble (D.12.A.75 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Raise the steering axle with an adequate lifting

device.
Remove the steering tyre from the combine by
loosening the nuts.
ZDA7565A 1
2. Loosen the four bolts (1) to remove the dust cover

(2).
ZDA7566A 2
3. Remove the cotter pin (3) and turn off the castle
nut (4).
ZDA7567A 3
12135 1 02/07/2004
D.12.A / 5
4. Slide the washer (5) and the inner bearing (6) from
the spindle.
Remove the hub casting (7).
ZDA7568A 4
5. Slide the inner bearing (8) from the spindle.
ZDA7569A 5
6. Remove the seal (9) and the cover plate (10), if

necessary.
ZDA7555A 6
7. Using a soft punch, to remove the outer bearings

out from the hub casting.
ZDA7554A 7
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D.12.A / 6
Hub - Assemble (D.12.A.75 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Install new outer bearings on both sides into the

hub casting.
ZDA7556A 1
2. Install the cover plate (10) and the seal (9) onto the
spindle.
ZDA7555A 2
3. Install the inner bearing (8) to the spindle.
ZDA7569A 3
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D.12.A / 7
4. Insert the spindle (11) into the pre-assembled hub

casting (7).
NOTE: Fill up the cavity completely with grease NLGI-2.
ZDA7557A 4
5. While holding the assembly in position, set the inner

bearing (6) onto the spindle with the tapered side
in. Slide the washer (5) on behind the bearing and
turn on the castle nut (4).
ZDA7568A 5
6. Tighten the nut (4) with a torque between 55 - 65

Nm. (41 - 48 lb ft)
Line up the nut with the cotter pin hole in the spindle.
If required, turn the nut in the loosen direction.
ZDA7567A 6
7. Install the cover (2) with the four bolts (1).

NOTE: Fill up the cover (2) completely with grease
NLGI-2.
ZDA7566A 7
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D.12.A / 8
Index
TRAVELLING - D
REAR AXLE - 12.A
Hub - Assemble (D.12.A.75 - F.10.A.20) 7

CS540, CS640, CS520, CS660
Hub - Disassemble (D.12.A.75 - F.10.A.25) 5
CS540, CS640, CS520, CS660
Hub - Exploded view (D.12.A.75 - C.10.A.20) 3
CS540, CS640, CS520, CS660
Hub - Sectional view (D.12.A.75 - C.10.A.30) 4
CS540, CS640, CS520, CS660
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D.12.A / 9
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D.12.A / 10
TRAVELLING - D
2WD-4WD SYSTEM Hydrostatic - 14.E
CS540
CS640
CS660
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D.14.E / 1
Contents
TRAVELLING - D
FUNCTIONAL DATA
2WD-4WD SYSTEM Hydrostatic - Static description (D.14.E - C.30.A.20) 3

CS540, CS640, CS660
Control valve
Control valve - Static description (D.14.E.14 - C.30.A.20) 5
CS540, CS640, CS660
Motor
Motor - Hydrostatic schema (D.14.E.28 - C.20.B.25) 19
CS540, CS640, CS660
Motor - Static description (D.14.E.28 - C.30.A.20) 20
CS540, CS640, CS660
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D.14.E / 2
TRAVELLING - 2WD-4WD SYSTEM Hydrostatic
2WD-4WD SYSTEM Hydrostatic - Static description (D.14.E -

C.30.A.20)
CS540, CS640, CS660
The powered rear axle is available as a factory installed or field installed option. This system will provide additional
traction when the machine is operated in tough field conditions. The system can be engaged or disengaged
electronically by a switch in the operators cab.
Both rear wheels are driven by hydraulic motors and the system receives its oil supply directly from the hydrostatic
pump. The high pressure lines from the hydrostatic pump supply the wheel motors through an ‘EQUA-TRAC II™’
control valve mounted near the rear axle.
The powered rear axle system operates as a function of the main hydrostatic drive system. A standard hydrostatic
system utilizes one pump and one drive motor (transmission mounted), whereas the powered rear axle system
utilizes one pump and three motors (one transmission mounted and two wheel mounted).
The wheel motors are cam lobe type units with a fixed displacement. The amount of wheel torque obtained from the
wheel motors is directly related to the hydrostatic system pressure. The higher the system pressure the greater
the wheel torque will be.
NOTE: It is not necessary to synchronize the front wheels (transmission mounted pump driven) with the rear wheels
(wheel motor driven) as the system pressure and hydraulic fluid flow hydraulic will do this automatically.
It is very important to maintain traction to the front wheels. If a front wheel loses traction and begins to slip, the
system pressure will lower. The spinning wheel requires less pressure to rotate. The oil in the pressure lines will
take the least path of resistance, therefore the amount of power assistance from the rear wheels will be reduced
because of the lower pressure. Shifting to a higher gear (if possible) will reduce the amount of torque at the front
wheels to stop the wheel slippage. Also, lightly touching the brakes will help.
NOTE: EQUA-TRAC II™ is a Registered Trademark of Tuthill Transport Technologies
12136 1 02/07/2004
D.14.E / 3
ZDF0762A 1
Powered Rear Axle
1 Equa-Trac II control valve 2 Right wheel motor

3 Left wheel motor 4 Forward high pressure inlet line "A"
5 Reverse high pressure inlet line "B" 6 Return to tank (reservoir) line
7 Motor case drain line 8 Hydrostatic oil reservoir
9 Hydrostatic pump 10 Hydrostatic drive motor
11 Drain hose 12 To hydrostatic oil cooler
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D.14.E / 4
Control valve - Static description (D.14.E.14 - C.30.A.20)

CS540, CS640, CS660
Introduction
The EQUA-TRAC II control valve block assembly is mounted near the rear axle and is a two tier valve.The upper tier
contains the forward and reverse inlet pressure ports, selector spool valve, reverse flow divider, reverse check valve
and reverse drive pressure outlet ports.The lower tier contains the low pressure shuttle valve, solenoid valve, forward
flow divider, forward check valve and forward drive pressure outlet ports.The low pressure shuttle valve, solenoid
valve and selector spool supply and control the oil supply to both upper and lower tier valves of the assembly.
ZDF0553A 1
EQUA-TRAC II Control valve assembly
1 E-T II valve block 2 Solenoid valve

3 Forward pressure inlet 4 Reverse pressure inlet
5 Left wheel motor reverse pressure port 6 Left wheel motor forward pressure port
7 Right wheel motor reverse pressure port 8 Right wheel motor forward pressure port
9 Pilot pressure to engage port 10 Reverse system pressure test port
11 Pilot pressure to disengage port 12 Forward system pressure port
13 Valve selector spool location
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D.14.E / 5
DS00M07 2
Cross section of Equa-Trac II control valve upper tier
1 Solenoid valve passage 2 Selector spool

3 Spring 4 Case drain orifice
5 Pilot pressure to engage port 6 Lower tier supply passage
7 Flow dividers 8 Spring
9 Spring 10 Check valve ball seat
11 Check valve ball 12 Check valve spring
13 Reverse outlet pressure ports 14 Pilot pressure to disengage port
15 (F). Forward inlet pressure port 16 (R). Reverse pressure port
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D.14.E / 6
Low pressure shuttle valve

The low pressure shuttle valve provides hydraulic fluid under charge (pilot) pressure to the solenoid valve to
engage or disengage the PRA system. The solenoid valve, in turn, supplies hydraulic fluid under charge pressure
to either end of the selector spool to move the spool. Depending upon what direction the spool moves, hydraulic
fluid to the wheel motors will be switched “ON" or “OFF". The charge pressure is available from the return side
of the PRA hydrostatic system.
The spacer (2) always holds one of the check balls, (3), (4), off the seat in the valve cavity. This ensures charge
pressure is always available, even if the combine’s main hydrostatic system is in neutral. When the combine is
driven forward, the forward side “F" receives high pressure flow and the reverse side “R" is low pressure (charge
pressure). The high pressure on the forward side will seat the check ball (3) which will move the spacer (2) to unseat
the opposite check ball, on the forward side will seat the forward check ball (3), which will move the spacer (2)
to unseat the reverse check ball (4) on the reverse side of the valve. The pressure will flow past the check ball
(4) and the spacer (2) through the passage (5) to the solenoid valve (1).
When the combine is in reverse, the reverse side “R" receives the high pressure flow and the forward “F" side
becomes low pressure (charge pressure). The reverse check ball (4) will seat, and will move the spacer (2)
unseating the forward check ball (3). This allows hydraulic fluid under charge pressure to flow past the check ball (3)
and the spacer (2) into the passage (5) to the solenoid valve.
The solenoid valve determines which side of the selector spool charge pressure is directed to, depending upon
whether or not current is being supplied to the solenoid.
DS00M058 3
1 Solenoid valve location 2 Spacer

3 Forward check ball 4 Reverse check ball
5 Oil passage
12136 1 02/07/2004
D.14.E / 7
Forward and reverse flow divider valves

There are two flow divider valve assemblies in the Equa-Trac II valve block, one for the forward drive and one for the
reverse drive. Each flow divider valve assembly is a split spool valve and contains two separate flow dividers.
If traction is lost to one rear wheel (wheel slip), the drive pressure to that wheel will have the least resistance and
the pressure will fall, making the wheel spin faster.
To compensate for this the higher pressure on the non-slipping wheel side of the flow divider will move the flow
divider valve assembly towards the lower pressure (slipping wheel) side, limiting the hydraulic fluid flow to the
slipping wheel at the same time maintaining the pressure on the non-slipping wheel.
When the drive pressure equalizes in both wheel motor drive lines, the flow divider will move back to the center
position.
The flow divider also limits the maximum hydraulic fluid flow to each wheel motor. If both wheel motors should begin
to spin, the split flow dividers will separate due to the pressure acting on the 8.33 mm (0.328 inch) orifice (4) in each
half of the spool. As the spools move apart the pressure to each drive motor will be limited to approximately 60.5
litres/min. (16 gal/min. ). The rear wheel drive system is therefore limited to a total of 121 litres/min. (32 gal/min.).
DS00M069 4
1 End cap 2 Spring (2 per valve)

3 Flow divider valve (2 per valve) 4 Orifice 8.33 mm (0.328 inch )
12136 1 02/07/2004
D.14.E / 8
Forward and reverse check valves

There are two check valve assemblies in the Equa-Trac II valve block, one for the forward drive and one for the
reverse drive. Each check valve assembly contains two check ball seats, two check balls and one spring.
The check valves prevent the full amount of return hydraulic fluid (at charge pressure) from the wheel motors from
flowing back through the check valve seats and flow divider orifice(s). This hydraulic fluid flow would create a large
pressure drop. The return hydraulic fluid pressure from the wheel motors will move the check balls off their seats
allowing some oil to flow through the check valve and through the center passage. The remaining oil will flow into
each end of the flow divider, past the selector spool to the return side of the hydrostatic pump.
DS00M070 5
1 Check valve seat (2 per valve) 2 Check valve ball (2 per valve)
3 Spring (1 per valve)
12136 1 02/07/2004
D.14.E / 9
E-T II Valve operation — Off position

(Reference Figures 6 and 7)
NOTE: References to directions are as if viewing the valve from the rear, facing the front of the combine.
When the PRA switch in the combine cab is in the “OFF" position, current is no longer supplied to the solenoid valve
(1). This causes the spring loaded spool in the solenoid to move away from the solenoid coil. When this happens,
hydraulic fluid flow from the low pressure spool will be closed off from port (A) to port (B) (which flows to the
pressure to engage side of the selector spool (2) Fig.7, in the ON position) and allow fluid to flow from port (A) to
port (C) (pressure to disengage side of the selector spool).
The return spring (3) Fig.7, and charge pressure directed from the low pressure spool, through port (C) of the
solenoid valve, and through the drilled passage (14) Fig.7, will move and keep the spool (2), Fig.7, to the left
side of the spool bore. This is the disengaged position for the spool and the forward and reverse high pressure
ports are closed off.
The rear wheels of the combine will now “free wheel". As the wheels rotate, the wheel motor pistons are pushed
back into their bores. The hydraulic fluid behind the pistons is directed back to the wheel motor supply/return ports,
12, 13, Fig.7, of the E-T II valve. From there, the fluid from the right wheel motor flows through the flow dividers
(7), and the right check valve (8) and center passage (9). Hydraulic fluid then flows to the left side wheel motor
reverse supply/return port (12) and to the selector spool (2). Hydraulic fluid that exits the valve at the reverse
supply/return port (12) and from the left wheel motor is directed back to the solenoid valve via external tube where
the fluid drains back to tank.
DS00M060 6
A. Oil supply from low pressure spool

B. From left side of selector spool via external line
C. To right side of selector spool
D. To case drain
12136 1 02/07/2004
D.14.E / 10
50016593 7
Cross Section of Equa-Trac II control valve - Off position
12136 1 02/07/2004
D.14.E / 11
E-T II Valve operation — Intermediate position

(Reference figures 8,9, and 10)
When the rear wheel drive is switched “ON", the system will momentarily go into an intermediate position. The
intermediate position allows hydraulic fluid under charge pressure to fill the system and wheel motors before full
drive pressure is achieved. This reduces the shock load exerted on the pistons and motor housing.
When the PRA switch in the combine cab is turned to the “ON" position, current is supplied to the solenoid valve (1).
This energizes the coil and causes the spring loaded spool to move towards the coil. Hydraulic fluid under charge
pressure will flow through the solenoid valve from port A to port B and to the pressure to engage (left) side (5) of
the selector spool (2) Fig.9, in the E-T II valve through an external tube.
As the selector spool (2), Fig.9, moves left, against the pressure of the spring (3) and will momentarily allow
hydraulic fluid under charge pressure to enter both forward and reverse flow dividers (7), Fig. 9, and (17), Fig.10,
through the feathering lands (16), Fig.9, on the selector spool. Hydraulic fluid flowing through the upper (9), Fig.9,
and lower (6), Fig.10, center channels will keep the check valves (8), Fig.9 and (20), Fig.10, closed. The hydraulic
fluid will then flow through the forward (18), (19), Fig.10, and reverse (12), (13), Fig.9, pressure supply/return
ports to the wheel motors.
The hydraulic fluid on the pressure to disengage (right) side of the selector spool (2), Fig.9, will flow through the
drilled passage (14), Fig.9, to port (C) of the solenoid valve (1). The hydraulic fluid will flow through the valve and
exit at port (D) and out of the E-T II valve through the case drain. The hydraulic fluid then returns to tank.
DS00M06O 8

B. From right hand side of selector spool via external line
C. From right side of selector spool
D. To case drain
12136 1 02/07/2004
D.14.E / 12
50016594 9
Cross section of Equa-Trac II Control valve upper tier - Intermediate position
DS00M068 10
Cross section of Equa-Trac II Control valve lower tier - Intermediate position
12136 1 02/07/2004
D.14.E / 13
E-T II Valve operation — ON position

When the rear wheel drive is switched “ON", the system will momentarily go into an intermediate position to fill the
wheel motors with hydraulic fluid. When the system is full, the selector spool will move completely to the right in the
E-T II valve to the “ON" position, allowing the wheel motors to be driven.
When the PRA switch in the combine cab is turned to the “ON" position, current is supplied to the solenoid valve
(1), Fig.11. This energizes the coil and causes the spring loaded spool to move towards the coil. Hydraulic
fluid under charge pressure will flow through the solenoid valve from port (A) to port (B) and to the pressure to
engage (left) side (5) of the selector spool (2), Fig.12, in the E-T II valve through an external tube. The hydraulic
fluid shifts the selector spool to the right and once the system is full of hydraulic fluid, the spool will shift fully to
the right against the spring (3).
12136 1 02/07/2004
D.14.E / 14
Forward
NOTE: The selector spool controls whether or not hydraulic fluid flows to the wheel motors, but does not control
forward or reverse movement in the wheel motors.
When high pressure hydraulic fluid is supplied to the forward pressure port, (F), Fig. 12
the selector spool allows the hydraulic fluid to flow past the spool land (21), Fig.12, through the center passage (6),
Fig.12, on lower tier of the valve, to the flow dividers (17), Fig.12. Hydraulic fluid also flows to the forward check
valves (10), Fig.12, keeping the valves closed. This assures hydraulic flow is directed out of the valve to the wheel
motors. From the flow dividers high pressure fluid is directed out of the forward pressure supply/return ports (18),
(19), Fig.12, to the wheel motors. The high pressure oil will drive the motors forward. If the flow of drive oil should
differ from one motor to the other (loss of traction to one wheel), the flow dividers (17), Fig.12 will compensate for
the differential by shifting in the E-T II valve. Refer to the flow divider description of operation described previously.
Return hydraulic fluid from the wheel motors will flow into the reverse pressure supply/return ports (12), (13), Fig.13.
The fluid is then directed to the flow dividers (7), and reverse check valves (8), Fig.13. The check valves will open
when hydraulic flow exceeds the amount of fluid allowed to flow through the 8.33 mm (0.328 inch ) orifice in each
flow divider. The hydraulic fluid will flow through the center passage (9), Fig.13 past the selector spool land (22),
Fig.12, and out of the reverse high pressure port, (R), Fig.12.
The hydraulic fluid on the pressure to disengage (right) side of the selector spool (2), Fig.12, will flow through the
drilled passage (14), Fig.12, to port (C) of the solenoid valve (1). The hydraulic fluid will flow through the valve and
exit at port (D) and out of the E-T II valve through the case drain. The hydraulic fluid then returns to tank.
DS00M06O 11

B. To left side of selector spool via external line
C. From right side of selector spool
D. To case drain
12136 1 02/07/2004
D.14.E / 15
50016595 12
Cross section of Equa-Trac II control valve forward lower tier valves and upper tier selector spool- On -
Forward position
DS00M064 13
Cross section of Equa-Trac II control valve (Reverse valves upper tier) - On - forward position
12136 1 02/07/2004
D.14.E / 16
Reverse
NOTE: The selector spool controls whether or not hydraulic fluid flows to the wheel motors, but does not control
forward or reverse movement in the wheel motors
When high pressure hydraulic fluid is supplied to the reverse pressure port, (R), Fig14, the selector spool (2) Fig.14,
allows the hydraulic fluid to flow past the spool land (22), Fig.14, through the center passage (9), Fig.14, on lower
tier of the valve, to the flow dividers (7), Fig.14. Hydraulic fluid also flows to the reverse check valves (8), Fig.14,
keeping the valves closed. This assures hydraulic flow is directed out of the valve to the wheel motors. From the
flow dividers high pressure fluid is directed out of the forward pressure supply/return ports (12), (13), Fig.14, to the
wheel motors. The high pressure oil will drive the motors in reverse. If the flow of drive oil should differ from one
motor to the other (loss of traction to one wheel), the flow dividers (7), Fig.14 will compensate for the differential by
shifting in the E-T II valve. Refer to the flow divider description of operation described previously.
Return hydraulic fluid from the wheel motors will flow into the forward pressure supply/return ports (18), (19), Fig.15.
The fluid is then directed to the flow dividers (17) and forward check valves (10), fig.15. The check valves will open
when hydraulic flow exceeds the amount of fluid allowed to flow through the 8.33 mm (0.328 inch ) orifice in each
flow divider. The hydraulic fluid will flow through the center passage (6), Fig.15 past the selector spool land (21),
Fig.14, and out of the forward high pressure port, (F), Fig.14.
The hydraulic fluid on the pressure to disengage (right) side of the selector spool (2) Fig.14, will flow through the
drilled passage (14) Fig.14, to port (C) of the solenoid valve (1) Fig.11. The hydraulic fluid will flow through the valve
and exit at port (D), Fig.11, and out of the E-T II valve through the case drain. The hydraulic fluid then returns to tank.
50016595_231 14
Cross section of Equa-Trac II control valve (upper tier valves) - On - reverse position
12136 1 02/07/2004
D.14.E / 17
DS00M064_232 15
Cross section of Equa-Trac II control valve (Forward valves lower tier) - On - reverse position
12136 1 02/07/2004
D.14.E / 18
Motor - Hydrostatic schema (D.14.E.28 - C.20.B.25)

CS540, CS640, CS660
ZDF0519A 1
1. Equa-Trac valve assembly 1a. Low pressure shuttle valve

1b. Solenoid valve 1c. Selector spool
1d. Flow divider valve 1e. Flow divider valve
1f. Check valve 1g. Check valve
2. Wheel motor 3. Wheel motor
A. To oil reservoir B. Forward high pressure from pump ("A" port)
C. Reverse high pressure from pump ("B" port)
12136 1 02/07/2004
D.14.E / 19
Motor - Static description (D.14.E.28 - C.30.A.20)

CS540, CS640, CS660
Wheel motor operation

To start the drive cycle, hydraulic fluid under high pressure is delivered from the hydrostatic pump through the E-T
II valve and supplied equally to the high pressure port (1) of each motor. The hydraulic fluid is diverted through
passage (2) in the distributor block (3) and port (4) in the cylinder block (5).
The hydraulic fluid passage (2) and port (4) are partially aligned allowing oil to begin entering the cavity behind the
piston (6). The high pressure pushes the piston outwards causing roller to make contact with cam (7) just after the
peak (highest point) of the lobe. This contact causes the cylinder block (5) to start rotating.
20013707 1
12136 1 02/07/2004
D.14.E / 20
Full supply position

As the piston and the roller (1) makes its way towards the bottom (valley) (2) of the cam lobe, the MAXIMUM (full)
supply of high pressure hydraulic fluid momentarily is directed through the aligned ports (3) of the distributor (4)
(remaining stationary) and the cylinder block (5) (rotating) with continuation on to the piston (1). The hydraulic
fluid supply then begins to taper off as the piston approaches the bottom of the cam lobe (2) towards the neutral
(no power drive) position.
ZDF0556A 2
Bottom neutral position
When the piston (1) is at the bottom of cam lobe (2), the hydraulic fluid supply is cut off. Ports (3) in the distributor (4)
and the cylinder block (5) are NOT in aligned with each other. In this neutral position the piston does NOT provide
drive power to the cylinder block however, the piston (and roller) remain in contact with the cam surface.
In order to continue driving power, another piston must take over for the first one to drive the cylinder block in the
direction shown, enabling the first piston to climb the next cam lobe in a smooth and uninterrupted manner.
ZDF0554A 3
Discharge position
As the piston (1) starts to climb the next cam lobe (2) ports (passages) (3) in the distributor (4) and the cylinder block
(5) begin to align with each other, thus starting the discharge cycle. This allows the hydraulic fluid (under charge
pressure) to return to the pump as another piston takes over the drive cycle.
ZDF0555A 4
12136 1 02/07/2004
D.14.E / 21
Top neutral position

During the final cycle of the piston (1) the piston continues to climb another cam lobe (2). As this happens, ports (3)
in the distributor block (4) and the cylinder block (5) progressively close off the return oil flow as the piston (and
roller) reaches the top (neutral) position.
When the roller is at the top of the cam lobe the ports are no longer aligned, thus ending a full drive cycle. The
piston and its roller will then repeat the cycle starting with a gradual supply of high pressure oil, while other pistons
continue their cycles in a similar manner.
ZDF0557A 5
Wheel motor power distribution
ZDF0558A 6
1 Power stroke 2 Transition to return

3 Return stroke 4 Transition to power
5 Cam 6 Carrier
7 Piston 8 Manifold
9 Pressure oil 10 Oil in transition
11 Return oil
12136 1 02/07/2004
D.14.E / 22
Pressure oil (9) is routed through the inner cover to the manifold (8). Each of the 16 passages in the manifold is
timed to one ramp on the cam (5).
The oil manifold is pressed against the piston carrier (6) with only a thin film of oil separating the manifold and carrier
surfaces. The piston carrier is splined to the axle. Pressure oil is fed from the pressure passages in the manifold
through passages in the carrier and into the piston bores.
Return oil (11) is routed from piston bores, through the carrier passages and into the manifold return passages.
The cam lobe motor is designed so there are two pistons doing the same thing at equal distances around the motor.
This gives a force balance on the carrier and axle assembly.
With motor engaged, one group of pistons (1) is in power stroke.
As the piston follower is forced down the cam ramp, the carrier is forced to turn. Group (3) pistons push return oil
(11) back through the manifold.
Pressure (10) indicates oil in transition from one port to another. As carrier turns, pistons (4) at the top of the lobes
begin their power stroke and the pistons (2) at the bottom begin their return stroke.
As one group ends its power stroke another group has begun. This overlapping of strokes, both power and return,
serve to smooth the power (torque) applied to the axle.
SYSTEM ENGAGED
Since each wheel motor contains 10 pistons and eight cam lobes, there are a total of 80 power strokes by the
pistons in one revolution of the cylinder block, which is splined to the wheel shaft. Each piston (and roller) travels up
and down each of the eight cam lobes in a smooth, uninterrupted manner, producing a constant torque output with a
low noise level. With an even number of pistons and cam lobes, the forces of the motor are balanced allowing the
motor bearings to be totally available to accept high radial and axial loads.
To change the direction of rotation of the motor, the input supply of high pressure oil is directed through the
(reverse) high pressure port and diverted through the distributor of the motor in a manner opposite to that of
the forward rotation of the motor.
SYSTEM DISENGAGE
When the drive system is shut off or disengaged, the E-T II valve prevents high pressure oil from being supplied to
the wheel motors.
In addition, the system pressure supply lines from the valve to the motors are opened directly to the reservoir
through the valve so that any pressure in these lines is dissipated.
The lack of pressure on either side of the pistons enables the pistons (and rollers) to retract into their cylinder bores
when the rollers are pushed inward by the cam lobes as the cylinder block rotates. With the rollers clear of the cam
lobes, the cylinder block and wheel shaft are able to rotate in a “free - wheeling" (non-drive) mode.
12136 1 02/07/2004
D.14.E / 23
Index
TRAVELLING - D
2WD-4WD SYSTEM Hydrostatic - Static description (D.14.E - C.30.A.20) 3

CS540, CS640, CS660
Control valve - Static description (D.14.E.14 - C.30.A.20) 5
CS540, CS640, CS660
Motor - Hydrostatic schema (D.14.E.28 - C.20.B.25) 19
CS540, CS640, CS660
Motor - Static description (D.14.E.28 - C.30.A.20) 20
CS540, CS640, CS660
12136 1 02/07/2004
D.14.E / 24
TRAVELLING - D
STEERING Hydraulic - 20.C
CS540
CS640
CS520
CS660
12137 1 02/07/2004
D.20.C / 1
Contents
TRAVELLING - D
TECHNICAL DATA
STEERING Hydraulic - Special tools (D.20.C - D.20.A.40) 3

CS540, CS640, CS520, CS660
Control valve
Control valve - General specification (D.20.C.14 - D.40.A.10) 3
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
Control valve
Control valve - Static description (D.20.C.14 - C.30.A.20) 4
CS540, CS640, CS520, CS660
Control valve - Exploded view (D.20.C.14 - C.10.A.20) 5
CS540, CS640, CS520, CS660
Steering pump
Steering pump - Exploded view (D.20.C.21 - C.10.A.20) 6
CS540, CS640, CS520, CS660
Cylinder
Cylinder - Sectional view (D.20.C.26 - C.10.A.30) 7
CS540, CS640, CS520
CS540, CS640, CS520, CS660
CS540, CS640, CS660
SERVICE
Control valve
Control valve - Remove (D.20.C.14 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Control valve - Disassemble (D.20.C.14 - F.10.A.25) 11
CS540, CS640, CS520, CS660
Control valve - Assemble (D.20.C.14 - F.10.A.20) 14
CS540, CS640, CS520, CS660
Control valve - Install (D.20.C.14 - F.10.A.15) 18
CS540, CS640, CS520, CS660
Cylinder
Cylinder - Service instruction (D.20.C.26 - F.10.A.05) 19
CS540, CS640, CS520, CS660
12137 1 02/07/2004
D.20.C / 2
TRAVELLING - STEERING Hydraulic
STEERING Hydraulic - Special tools (D.20.C - D.20.A.40)

CS540, CS640, CS520, CS660
Description
Steering valve seal tool
Tool No.
380000305
ZDF0736A 1
Control valve - General specification (D.20.C.14 - D.40.A.10)

CS540, CS640, CS520, CS660
Specifications Steering axle

Fixed + PRA ASA
Motor displacement 160 cc (9.76 in/rev) 160 cc (9.76 in/rev)
Nominal flow rating 18.5 l/min (4.9 gal/min) 18.5 l/min (4.9 gal/min)
Setting pressure relief valve 160-165 bar (2320-2393 psi) 140-145 bar (2030-2103 psi)
Setting shock valves 220-235 bar (3190-3408 psi) 200-215 bar (2900-3118 psi)
12137 1 02/07/2004
D.20.C / 3
Control valve - Static description (D.20.C.14 - C.30.A.20)

CS540, CS640, CS520, CS660
The Danfoss steering valve OSPC 160 ON consists of a selector valve and an orbit pump.
The purpose of having an orbit pump built in the valve is to have a perfect ratio between the steering wheel and the
steering cylinder, and to guarantee a manual operation in case of breakdown.
The steering wheel controls the selector valve and the orbit pump. The valve sleeve is held in neutral by leaf springs.
These leaf springs only allow a minor shifting between the valve sleeve and the spool when turning the steering
wheel.
35_35-2_02 1
Four ports discharge into the valve body.
P: Pressure inlet
T: Return to reservoir
L and R: Left and Right cylinder connection to steering
A ball is fitted between the ports (P) and (T). During normal operation the ball is pushed on its seat, closing the
connection between (P) and (T).
When no oil under pressure (e.g. failure of hydraulic pump) flows from the pump into port (P), steering will still be
possible as the return oil pushes the ball from its seat and flows into suction line (P).
The pressure relief valve, situated between inlet (P) and return (T).
The double-acting shock-valve situated between ports (L) and (R).
ZDF0731A 2
12137 1 02/07/2004
D.20.C / 4
Control valve - Exploded view (D.20.C.14 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDF0724A 1
Steering control valve
1 Dust seal ring 2 Housing spool/sleeve

3 Ball 4 Thread bushing
5 O-ring 6 Check valve
7 Bearing assembly 8 Bushing with pin
9 Ball 10 Ring
11 Cross pin 12 Set of springs
13 Shaft 14 Complete shock valve
15 O-ring 16 Distributor plate
17 Gear wheel set 18 O-ring
19 End cover 20 Washer
21 Spring for relief valve 22 Screw with pin
23 Screw 24 Identification plate
25 Pressure relief valve
12137 1 02/07/2004
D.20.C / 5
Steering pump - Exploded view (D.20.C.21 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDF0844A 1
Steering pump
1 Pump housing 2 Housing cover

3 Radial-lip-type oil seal 4 Housing cover
5 Toothed gear 6 Toothed gear
7 Protective cap 8 Protective cap
9 Bushing 10 Bushing
11 Head screw 12 Straight pin
13 Driver 14 O-ring
15 Straight pin 16 Set of seals
NOTE: Tighten the screws (11) with a torque between 12 - 16 Nm. (9 - 12 lb ft)
12137 1 02/07/2004
D.20.C / 6
Cylinder - Sectional view (D.20.C.26 - C.10.A.30)

CS540, CS640, CS520
CAUTION
Z027 - This component has an important safety function. Do not attempt to repair it unless you are totally
familiar with it. Only use new genuine parts.
ZDF0723A 1
Steering cylinder (FIXED STEERING AXLE)
1 Cylinder 2 Piston rod

3 Piston guide ring 4 Scraper ring
5 Seal 6 O-ring
7 O-ring 8 Guide ring
9 Seal 10 Cylinder head
11 Bolt (torque 91-111 Nm)
12137 1 02/07/2004
D.20.C / 7

CS540, CS640, CS520, CS660
ZDF0720A 1
Steering cylinder (ADJUSTABLE STEERING AXLE)
1 Bolt (torque 43-51 Nm) 2 Washer

5 Seal 6 Cylinder
7 O-ring 8 O-ring
9 Guide ring 10 Cylinder head
11 Piston rod 12 Seal
12137 1 02/07/2004
D.20.C / 8

CS540, CS640, CS660
ZDF0845A 1
Steering cylinder ( POWER REAR AXLE)
12137 1 02/07/2004
D.20.C / 9
Control valve - Remove (D.20.C.14 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Place a clean suitable container under the fittings of

the valve to catch the oil.
Loosen the four fittings (1).
ZDF0545A 1
2. Remove the steering column cover. Refer

to Steering column - Remove (D.20.B.40 -
F.10.A.10).
3. Loosen the four bolts (1) from inside the cab.
NOTE: This job has to be done by two persons.
ZDF0544A 2
12137 1 02/07/2004
D.20.C / 10
Control valve - Disassemble (D.20.C.14 - F.10.A.25)

CS540, CS640, CS520, CS660
CAUTION
Preceding remarks:
Make sure that the special tool STEERING Hydraulic - Special tools (D.20.C - D.20.A.40) is available before
disassembling the steering valve. This special tool is used to fit new seals in the valve body.
1. Place the shaft in the rotor so that the drive slot

forms a straight line with the rotors hollows [see
arrows].
Make sure that the ball between ports (P) and (T)
is correctly seated when the special screw, with the
roll pin, is fitted.
ZDF0562A 1
2. Clamp the steering valve in a vice (as shown).

Remove the end plate (1) by loosening the bolts (2).
ZDF0563A 2
3. Remove the end plate (1), together with the rotor

housing (3) and the rotor, as well as the O-rings
from both sides of the rotor housing.
ZDF0564A 3
12137 1 02/07/2004
D.20.C / 11
4. Remove the spacer (4), if fitted and the drive shaft

(5).
ZDF0565A 4
5. Remove the intermediate plate (6) and the O-ring

(7).
ZDF0566A 5
6. Unscrew the stop (8).
ZDF0567A 6
7. Remove the ball (9) out of the rotor housing and the
two suction valves at (10) (2 pins and 2 balls).
ZDF0568A 7
12137 1 02/07/2004
D.20.C / 12
8. Press the valve spool out of the valve housing. The

valve housing should be held in a vertical position
as shown.
ZDF0569A 8
9. Subsequently remove the washer (1), the needle

bearing (2), the bearing race (3) and the ring (4).
Press out the cross pin (5) and remove the leaf
springs (6).
Remove the valve spool from the valve sleeve.
ZDF0570A 9
10. The ring (7) and the O-ring (8) can now be removed
from the steering valve body. These seals are
located in the neck of the steering valve body.
ZDF0571A 10
11. Clean all the parts carefully. Prior to assembly it

is recommended to replace all O-rings (1), the
washers (2), and the plate springs (3) with new
parts.
Before assembly, lubricate all parts with hydraulic
oil.
ZDF0559A 11
12137 1 02/07/2004
D.20.C / 13
Control valve - Assemble (D.20.C.14 - F.10.A.20)

CS540, CS640, CS520, CS660
CAUTION
Preceding remarks:
Make sure that the special tool STEERING Hydraulic - Special tools (D.20.C - D.20.A.40) is available before
disassembling the steering valve. This special tool is used to fit new seals in the valve body.
1. Place the shaft in the rotor so that the drive slot

forms a straight line with the rotors hollows [see
arrows].
Make sure that the ball between ports (P) and (T)
is correctly seated when the special screw, with the
roll pin, is fitted.
ZDF0562A 1
2. Install the leaf springs (1) symmetrically in the spool

(2) so that the spring ends open when installed
correctly.
ZDA0681A 2
3. Assemble the spool (2) and the sleeve (3), and

secure it with the cross pin (1).
ZDA0682A 3
12137 1 02/07/2004
D.20.C / 14
4. Install the ring (5), the bearing race (6), the needle
bearing (7) and the washer (8) on the valve spool in
the above-mentioned order.
ZDA0683A 4
5. Grease the ring (1) and the O-ring (2).

Place the subassembly of the rings (1) and (2)
around the spindle of special tool. STEERING
Hydraulic - Special tools (D.20.C - D.20.A.40).
ZDA0684A 5
6. Push the sleeve of the special tool over the seal

rings on the spindle until there is some resistance.
ZDA0685A 6
7. Lead the special tool, with the seal rings, into the
bore in the valve housing until the tool sleeve
touches the bottom.
ZDA0686A 7
12137 1 02/07/2004
D.20.C / 15
8. Hold the sleeve in position and push the spindle

downwards, turning it at the same time so that the
subassembly of the rings (1) and (2) (see fig.5)
seats in the groove.
First remove the spindle of the special tool and then
the sleeve.
ZDA0687A 8
9. Install the spool with all its parts in the valve

housing, turning it slowly at the same time.
ZDA0688A 9
10. Place the ball (1) in the correct hole and retain with
the stop (2). Place the two suction valves (two pins
and two balls) 180 degrees turned away from the
position of the ball (1).
ZDA0689A 10
11. Install the O-ring (7) and the intermediate plate (6).
ZDF0566A_53 11
12137 1 02/07/2004
D.20.C / 16
12. Now refit the rotor housing (3) with rotor and drive
shaft with the coupling (4), together with the new
seal rings.
Place the coupling (4), so that the drive slot (5)
forms a straight line with the rotor hollows. Turn the
rotor housing until the drive slot (5) engages with
the cross pin (1) (fig.3) in the spool.
Install the spacer (4).
ZDA0690A 12
13. Reinstall the end cap (2) and turn the rotor housing
until all the holes are correctly aligned. Check
whether the ball (1) is in its proper position.
Install the bolt and the pin assembly together with a
new washer to ensure the ball (1) remains correctly
seated.
ZDF0721A 13
14. Install the remaining bolts with new washers and

tighten the bolts diagonally to a torque of 30 Nm
(22 lb ft).
Install the adapter with new O-rings.
ZDF0722A 14
12137 1 02/07/2004
D.20.C / 17
Control valve - Install (D.20.C.14 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the valve (6) in place.

Install the four bolts (2) with the dampers (3) (from
series 1364 onwards).
Install the flange (4), and the washer (5).
Tighten the four bolts (2) with a torque between 30
- 35 Nm.(22 - 26 lb ft)
ZDFD0552A 1
2. Install and tighten the four hydraulic lines and

tighten the fittings (1).
Add hydraulic oil in the oil reservoir, if necessary.
ZDF0545A_52 2
Next operation: Refer to Steering column - Install (D.20.B.40 - F.10.A.15).
12137 1 02/07/2004
D.20.C / 18
Cylinder - Service instruction (D.20.C.26 - F.10.A.05)

CS540, CS640, CS520, CS660
All seals can be replaced and are made available in a seal kit.
Make sure to order the correct seal kit.
"Unloading tube cylinder with a detachable cylinder head"
Proceed as follows:
1. Loosen the cylinder head (1) by turning the head

clock wise, using a punch mark and a hammer.
ZDF0729A 1
2. Pull out the piston rod (2).
ZDF0728A 2
3. Remove the bolt (3) and the cylinder sleeve (4).

Now is it possible to remove the cylinder head (1)
from the piston rod (2).
Remove all the seals.
ZDF0734A 3
12137 1 02/07/2004
D.20.C / 19
4. Clean and oil the piston rod (2), the cylinder sleeve
(4) and the seals and reassemble them.
Slide the cylinder head (1) onto the piston rod (2).
Install the cylinder sleeve (4) and tighten the bolt (3).
ZDF0734A 4
5. Slide the pre-assembled piston rod (2) in the

cylinder housing.
Turn the cylinder head (1) counter-clockwise onto
the cylinder housing.
ZDF0728A_72 5
6. Tighten the cylinder head, using a punch mark and

a hammer.
12137 1 02/07/2004
D.20.C / 20
Index
TRAVELLING - D
Control valve - Assemble (D.20.C.14 - F.10.A.20) 14

CS540, CS640, CS520, CS660
Control valve - Disassemble (D.20.C.14 - F.10.A.25) 11
CS540, CS640, CS520, CS660
Control valve - Exploded view (D.20.C.14 - C.10.A.20) 5
CS540, CS640, CS520, CS660
Control valve - General specification (D.20.C.14 - D.40.A.10) 3
CS540, CS640, CS520, CS660
Control valve - Install (D.20.C.14 - F.10.A.15) 18
CS540, CS640, CS520, CS660
Control valve - Remove (D.20.C.14 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Control valve - Static description (D.20.C.14 - C.30.A.20) 4
CS540, CS640, CS520, CS660
CS540, CS640, CS520
CS540, CS640, CS520, CS660
CS540, CS640, CS660
Cylinder - Service instruction (D.20.C.26 - F.10.A.05) 19
CS540, CS640, CS520, CS660
STEERING Hydraulic - Special tools (D.20.C - D.20.A.40) 3
CS540, CS640, CS520, CS660
Steering pump - Exploded view (D.20.C.21 - C.10.A.20) 6
CS540, CS640, CS520, CS660
12137 1 02/07/2004
D.20.C / 21
12137 1 02/07/2004
D.20.C / 22
TRAVELLING - D
STEERING Mechanical - 20.B
CS540
CS640
CS520
CS660
12138 1 02/07/2004
D.20.B / 1
Contents
TRAVELLING - D
SERVICE
Steering column
Steering column - Remove (D.20.B.40 - F.10.A.10) 3
CS540, CS640, CS520, CS660
Steering column - Install (D.20.B.40 - F.10.A.15) 4
CS540, CS640, CS520, CS660
12138 1 02/07/2004
D.20.B / 2
TRAVELLING - STEERING Mechanical
Steering column - Remove (D.20.B.40 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Pull off the adjusting knob (1).

Remove the screws (2) and take the upper cover
halves from the steering column.
ZEIL04CS0093A0B 1
2. Pull the left-hand side upper cover over the direction

indicator lever.
ZEIL04CS0032A0B 2
3. Lower the boot (3) to have access to the lower

screw of the cover.
Remove the two screws (4) of the both lower cover
halves.
ZEIL04CS0094A0B 3
4. With the covers removed, all internal steering

column components can be accessed.
ZEIL04CS0095A0A 4
12138 1 02/07/2004
D.20.B / 3
TRAVELLING - STEERING Mechanical
Steering column - Install (D.20.B.40 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Position the two lower halves of the steering column

covers and install the screws (4).
Secure the boot (3) to the lower cover halves.
ZEIL04CS0094A0B 1
2. Position the two upper cover halves of the steering

column and don’t forget to install the switch (5) and
the light indicator (6) between the cover halves.
ZEIL04CS0096A0B 2
3. Install and tighten the two screws (2).

Install the adjusting knob (1).
ZEIL04CS0093A0B 3
12138 1 02/07/2004
D.20.B / 4
Index
TRAVELLING - D
Steering column - Install (D.20.B.40 - F.10.A.15) 4

CS540, CS640, CS520, CS660
Steering column - Remove (D.20.B.40 - F.10.A.10) 3
CS540, CS640, CS520, CS660
12138 1 02/07/2004
D.20.B / 5
12138 1 02/07/2004
D.20.B / 6
TRAVELLING - D
SERVICE BRAKE Hydraulic - 30.C
CS540
CS640
CS520
CS660
12139 1 02/07/2004
D.30.C / 1
Contents
TRAVELLING - D
TECHNICAL DATA
SERVICE BRAKE Hydraulic - Torque (D.30.C - D.20.A.10) 3

CS540, CS640, CS520, CS660
Brake
Brake Disc - General specification (D.30.C.58.42 - D.40.A.10) 3
CS540, CS520
CS640, CS660
FUNCTIONAL DATA
Command
Command - Overview (D.30.C.05 - C.10.A.10) 4
CS540, CS640, CS520, CS660
Master cylinder
Master cylinder - Static description (D.30.C.27 - C.30.A.20) 5
CS540, CS640, CS520, CS660
SERVICE
SERVICE BRAKE Hydraulic - Bleed (D.30.C - F.35.A.25) 6

CS540, CS640, CS520, CS660
Command
Command - Adjust (D.30.C.05 - F.45.A.01) 8
CS540, CS640, CS520, CS660
Brake
Brake - Remove (D.30.C.58 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Brake - Install (D.30.C.58 - F.10.A.15) 12
CS540, CS640, CS520, CS660
Brake Lining - Replace (D.30.C.58.41 - F.10.A.30) 14
CS540, CS640, CS520, CS660
12139 1 02/07/2004
D.30.C / 2
TRAVELLING - SERVICE BRAKE Hydraulic
SERVICE BRAKE Hydraulic - Torque (D.30.C - D.20.A.10)

CS540, CS640, CS520, CS660
Allen screws brake shoe 260-270 Nm (192-200 lb ft)

Brake nipples 11-15 Nm (8-11 lb ft)
Brake Disc - General specification (D.30.C.58.42 - D.40.A.10)

CS540, CS520
Brake disc diameter 360 mm (14 - 3/16 in)
Brake Disc - General specification (D.30.C.58.42 - D.40.A.10)

CS640, CS660
12139 1 02/07/2004
D.30.C / 3
Command - Overview (D.30.C.05 - C.10.A.10)

CS540, CS640, CS520, CS660
ZDA7846A 1
1 Spring 2 Bolt
3 Brake pedal 4 Nut
5- 6 Pin
7 Push rod 8 Fork
9 Sealing 10 Nut
12139 1 02/07/2004
D.30.C / 4
Master cylinder - Static description (D.30.C.27 - C.30.A.20)

CS540, CS640, CS520, CS660
The two main cylinders (1) are mutually connected with the connectors (2) and (3), further with the pipe (4) to the
fluid reservoir (13) and with the pipes (5) to the brake cylinders.
Fluid from the fluid reservoir enters the brake main cylinder through the port (6) (pedal not engaged).
When both brake pedals are engaged, the port (6) is shut off by the seal (7), and fluid is pressed through the port (8)
and the pipes (5) to the brake cylinder. The ball (9) is lifted up in the both main cylinders (1) by the plunger (10).
When only one brake pedal is engaged, the port (6) is also shut off by the seal (7) and fluid is pressed through the
port (8) and the pipe (5) to the brake cylinder.
In the other main cylinder, the ball (9) is pressed down by the fluid pressure coming from the first cylinder through
the connector (2) and the seat (11). The fluid flow is stopped by the seal (12).
ZDA5249A 1
ZDA7838A 2
12139 1 02/07/2004
D.30.C / 5
SERVICE BRAKE Hydraulic - Bleed (D.30.C - F.35.A.25)

CS540, CS640, CS520, CS660

the combine.
2. Raise the header and engage the header safety
latch. Stop the engine.
3. Remove the cover plate (3).
NOTE: As the brake pedals must be depressed several
times while bleeding, this job has to be done with two
persons.
ZDA6061A_47 1
4. Bleed the left-hand side circuit:

Remove rubber stops from left-hand side bleed the
screws (1), (2) and (3).
ZDA8191A 2
5. Slide a transparent hose over bleed the screw (1) to

catch the oil while bleeding.
6. Open the bleed screw (1) and depress the left-hand
side brake pedal until fluid escapes.
Close the bleed screw (1).
7. Depress the left-hand side brake pedal several
times to build up a pressure.
8. Keep the pedal depressed.
9. Open the bleed screw (1) slightly to allow air and
fluid to escape.
10. Close the bleed screw (1) and release the brake
pedal.
11. Repeat steps 7 to 10 until fluid free of air bubbles
escapes through the bleed screw (1).
12139 1 02/07/2004
D.30.C / 6
12. Remove the transparent hose from the bleed

screw (1) and install the rubber stop. Repeat
steps 5 to 12 for the bleed screws (2) and (3).
Bleed the connection pipe between the two main
cylinders.
ZDA8191A_48 3
13. Bleeding the connection pipe between the two main

cylinders:
Remove rubber stops from right-hand side the bleed
screws (1), (2) and (3).
14. Slide a transparent hose over the right-hand side
bleed screw (1).
15. Open the right-hand side bleed screw (1).
16. Depress and hold the right-hand side brake pedal
depressed.
17. Depress the left-hand side brake pedal once and
keep it depressed.
18. Release the right-hand side brake pedal and then
the left-hand side brake pedal.
19. Repeat steps 16 to 17 until brake fluid free of air
bubbles escapes from the bleed screw (1).
20. Bleed the right-hand side circuit:
Depress the right-hand side brake pedal several
times to build up a pressure.
21. Keep the pedal depressed.
22. Open the bleed screw (1) slightly to allow air and
fluid to escape.
23. Close the bleed screw (1) and release the brake
pedal.
24. Repeat steps 20 to 23 until fluid free of air bubbles
escapes through the bleed screw (1).
25. Remove the transparent hose from the bleed
screw (1) and install the rubber stop. Repeat
steps 20 to 24 for the bleed screws (2) and (3).
26. Install rubber stops on the right-hand side bleed
screws.
12139 1 02/07/2004
D.30.C / 7
Command - Adjust (D.30.C.05 - F.45.A.01)

CS540, CS640, CS520, CS660
1. Disconnect the spring (1) of the both brake pedals

(3), using a rope.
ZDF0302A 1
2. Remove the cotter pin (5), the pin (6) and disconnect
the fork (8) of the both pedals.
ZDF0303A 2
3. Reinstall the pin (6), secure it with the cotter pin and
connect the springs (1) onto both pedals as shown.
Connect the both brake pedals together.
Keep the pedals (3) in the upper position. Ensure
that the both pedals touches the sealing (9).
Adjust the stops (bolt 10) against the pedal and
tighten the lock nuts of the both pedals (3).
IMPORTANT: Check that the both stops (10) touches the
both coupled pedals at the same time.
ZDF0304A 3
12139 1 02/07/2004
D.30.C / 8
4. Adjust the stop (bolt 2) (fig.5) with coupled brake

pedals so that there is a clearance "X" between 10
- 20 mm (3/8 - 3/4 in) (this is between the front
windscreen and the brake pedals).
ZDA7880A 4
5. After adjusting, tighten the bolt (2) with the lock nuts
of the both pedals.
Uncouple the brake pedals.
Disconnect the spring (1), using a rope.
ZDF0304B 5
6. Keep the pedal (3) in the upper position until they

touches the stop bolt (10). (see fig.3)
Loosen the nut (4).
Push in the push rod (7) to take away the internal
clearance.
Adjust the fork (8) so that the pin (6) can be installed.
Screw up the fork (8) onto the push rod (7) one turn.
Install the pin (6). Check that there is some
clearance "X" = +/- 0.8 mm (refer to Command -
Overview (D.30.C.05 - C.10.A.10))
After adjusting, tighten the nut (4).
ZDA78347A 6
7. Secure the pin (6) with the cotter pin (5).

Install the spring (1) of the both pedals, using a rope.
ZDA7836B 7
12139 1 02/07/2004
D.30.C / 9
Brake - Remove (D.30.C.58 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the brake line (1) between the upper and

lower brake shoes.
ZDA7830A 1
2. Turn the disc (1) until the holes in the disc aligns
with the Allen screws (2) and (3).
Remove the two Allen screws (2) and (3).
Remove the upper brake shoe (4).
ZDA7832A 2
3. Remove the special bolt (2) to make the line (3) free.
ZDA7831A 3
12139 1 02/07/2004
D.30.C / 10
4. Remove the two Allen screws (1) and (2).

Remove the lower brake shoe (3).
ZDA7833A 4
ZDA4211A 5
6. Remove the brake disc (2).

Proceed the same on the other side.
ZDF0402A 6
12139 1 02/07/2004
D.30.C / 11
Brake - Install (D.30.C.58 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the brake disc (2) on the output shaft of the

traction gearbox.
ZDF0402A 1
2. Secure the brake disc on the output shaft with the

retaining ring (1).
ZDA4211A 2

113) on the Allen screws (1) and (2).
Install the lower brake shoe (3) and tighten the Allen
screws (1) and (2) to a torque between 260 - 270
Nm (192 - 200 lb ft).
ZDA7832A_49 3
12139 1 02/07/2004
D.30.C / 12
4. Install the brake line (3) and tighten the nipple to a

Fix the brake line (3) to the traction gearbox with
the special bolt (2).
ZDA7831A 4

113) on the Allen screws (2) and (3).
Install the upper brake shoe (4) and tighten the
Allen screws (2) and (3) to a torque between 260 -
270 Nm (192 - 200 lb ft).
ZDA7832A 5
6. Install the brake line (1) between the upper and

lower brake shoes and tighten the nipples to a
Proceed the same on the other side.
ZDA7830A_50 6
12139 1 02/07/2004
D.30.C / 13
Brake Lining - Replace (D.30.C.58.41 - F.10.A.30)

CS540, CS640, CS520, CS660

the combine.
Raise the header and engage the header safety
latch. Stop the engine.
Remove the cover plate (3).
ZDA6061A_47 1
2. On the upper brake shoe, remove the two bolts (1)

and the cover (2).
ZDA5216A 2
3. Disconnect the electric wires at (3).

NOTE: Only the upper brake shoe linings have electrical
connectors.
ZDA5217A 3
12139 1 02/07/2004
D.30.C / 14
4. Remove the pins (4) out of the brake shoe and take
out the brake linings (5).
ZDA5218A 4
5. Check the condition of the seals (6). If necessary,

replace them.
NOTE: In case the seals are replaced, bleed the brakes
as described in SERVICE BRAKE Hydraulic - Bleed
(D.30.C - F.35.A.25) after the linings are replaced.
ZDA5219A 5
6. Push the brake cylinders in their housing to allow

the installation of new brake linings.
7. Install new brake linings.
8. Secure the brake linings with the pins (4) (fig.4) .
9. Connect the electric wires at (3) (fig.3).
10. On the lower brake shoe, remove the pins (4) out of
the brake shoe and take out the brake linings (5).
NOTE: On the lower brake shoe, there is no cover
installed.
IMPORTANT: Always replace the upper and the lower
brake linings at the same time.
ZDA5220A 6
11. Check the condition of the seals. If necessary,

replace them.
NOTE: In case the seals are replaced, bleed the brakes
as described in SERVICE BRAKE Hydraulic - Bleed
(D.30.C - F.35.A.25) after the linings are replaced.
12139 1 02/07/2004
D.30.C / 15
12. Push the brake cylinders in their housing to allow

the installation of new brake linings.
13. Install new brake linings.
14. Secure the brake linings with pins 4 (fig.6).
15. Proceed the same way on the other side.
16. Check the brake fluid level. If necessary,
remove brake fluid (refer to the CS Operator’s
Manual SECTION 4 - “LUBRICATION AND
MAINTENANCE", paragraph headed “Brake
system".
17. Check the brakes.
12139 1 02/07/2004
D.30.C / 16
Index
TRAVELLING - D
Brake - Install (D.30.C.58 - F.10.A.15) 12

CS540, CS640, CS520, CS660
Brake - Remove (D.30.C.58 - F.10.A.10) 10
CS540, CS640, CS520, CS660
CS540, CS520
CS640, CS660
Brake Lining - Replace (D.30.C.58.41 - F.10.A.30) 14
CS540, CS640, CS520, CS660
Command - Adjust (D.30.C.05 - F.45.A.01) 8
CS540, CS640, CS520, CS660
Command - Overview (D.30.C.05 - C.10.A.10) 4
CS540, CS640, CS520, CS660
Master cylinder - Static description (D.30.C.27 - C.30.A.20) 5
CS540, CS640, CS520, CS660
SERVICE BRAKE Hydraulic - Bleed (D.30.C - F.35.A.25) 6
CS540, CS640, CS520, CS660
SERVICE BRAKE Hydraulic - Torque (D.30.C - D.20.A.10) 3
CS540, CS640, CS520, CS660
12139 1 02/07/2004
D.30.C / 17
12139 1 02/07/2004
D.30.C / 18
TRAVELLING - D
PARKING BRAKE Mechanical - 32.B
CS540
CS640
CS520
CS660
12140 1 02/07/2004
D.32.B / 1
Contents
TRAVELLING - D
SERVICE
Command
Command - Adjust (D.32.B.05 - F.45.A.01) 3
CS540, CS640, CS520, CS660
12140 1 02/07/2004
D.32.B / 2
TRAVELLING - PARKING BRAKE Mechanical
Command - Adjust (D.32.B.05 - F.45.A.01)

CS540, CS640, CS520, CS660
CAUTION
Z007 - Before carrying out repair or maintenance work on the brake system, secure the machine safely in
place by placing adequate wedges against both traction and steering wheels.
1. Disengage the hand brake in the cab. (= bottom

position)
ZDA7882A 1
2. Loosen the two nuts (1) and the two bolts (2).
Check that dimension “X" is between 180 - 184
mm. (7-1/6 - 7-1/4 in) make sure that the cable (3)
is straight. (fig.3)
ZDA7847A 2
3. If not, adjust with the nuts (4) and (5).

After adjusting, tighten the nuts (4) and (5).
ZDA7876A 3
12140 1 02/07/2004
D.32.B / 3
TRAVELLING - PARKING BRAKE Mechanical
4. Simultaneously tighten the two bolts (2) by hand

until they touch the brake blocks.
Engage and disengage the hand brake in the cab a
few times.
Check the tightness of the two bolts (2). If possible,
tighten them simultaneously by hand. Turn them an
extra quarter of a turn with a spanner.
Engage and disengage the hand brake in the cab a
few times.
Loosen the two bolts (2) and tighten them
simultaneously by hand, after loosen the two bolts
(2) with 1/6 of a turn.
Tighten the locknuts (1). Ensure that the two bolts
(2) not turning with the nuts (1).
ZDA7847B 4
12140 1 02/07/2004
D.32.B / 4
Index
TRAVELLING - D
Command - Adjust (D.32.B.05 - F.45.A.01) 3

CS540, CS640, CS520, CS660
12140 1 02/07/2004
D.32.B / 5
PRINTED IN BELGIUM
12133 1 02/07/2004
REPAIR MANUAL
BODY AND STRUCTURE
CS540
CS640
CS520
CS660
12141 1 02/07/2004
E
Contents
BODY AND STRUCTURE - E
USER CONTROLS AND SEAT E.32.A

CS540, CS640, CS520, CS660
USER PLATFORM E.34.A

CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Heating system E.40.B

CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system E.40.C

CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning E.40.D

CS540, CS640, CS520, CS660
SAFETY SECURITY ACCESSORIES Safety E.50.B

CS540, CS640, CS520, CS660
12141 1 02/07/2004
E
USER CONTROLS AND SEAT - 32.A
CS540
CS640
CS520
CS660
12142 1 02/07/2004
E.32.A / 1
Contents
DIAGNOSTIC
Mirror
Mirror Left hand mirror - Testing (E.32.A.74.01 - G.40.A.20) 3
CS540, CS640, CS520, CS660
Mirror Right hand mirror - Testing (E.32.A.74.02 - G.40.A.20) 3
CS540, CS640, CS520, CS660
Mirror Interior mirror - Testing (E.32.A.74.03 - G.40.A.20) 5
CS540, CS640, CS520, CS660
Mirror Fuse - Testing (E.32.A.74.80 - G.40.A.20) 6
CS540, CS640, CS520, CS660
Mirror Switch - Testing (E.32.A.74.83 - G.40.A.20) 6
CS540, CS640, CS520, CS660
Mirror - Problem solving (E.32.A.74 - G.40.A.30) 8
CS540, CS640, CS520, CS660
12142 1 02/07/2004
E.32.A / 2
BODY AND STRUCTURE - USER CONTROLS AND SEAT
Mirror Left hand mirror - Testing (E.32.A.74.01 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the power mirror switch Less than 1 ohm. Open circuit between power mirror
connector S62. If good reading, continue with next switch connector S62 (pin B), circuit
Disconnect the left-hand power step. 250 (WT) and Left-hand power
mirror connector X104. mirror connector X104 (pin 4), circuit
Measure the resistance between 250 (GE).
connector S62 (pin B) and connector
X104 (pin 4).
2 Measure the resistance between Less than 1 ohm. Open circuit between power mirror
connector S62 (pin C) and connector If good reading, continue with next
switch connector S62 (pin C), circuit
X104 (pin 1 and 2). step. 249 (WT) and left-hand power mirror
connector X104 (pin 1 and 2), circuit
249 (PK).
connector S62 (pin D) and connector If good reading, the left-hand power switch connector S62 (pin D), circuit
X104 (pin 3). mirror circuits are okay. 248 (WT) and left-hand power mirror
(BL).
Mirror Right hand mirror - Testing (E.32.A.74.02 - G.40.A.20)

CS540, CS640, CS520, CS660
12142 1 02/07/2004
E.32.A / 3
CAUTION
WARNING

1 Disconnect the power mirror switch Less than 1 ohm. Mirror control relay K30.
connector S62. If good reading, go to test point 5. Open circuit between power mirror
Disconnect the right-hand power switch connector S62 (pin G), circuit
mirror connector X105. 246 (WT) and cab roof printed circuit
Measure the resistance between connector X129 (pin 2), circuit 246
connector S62 (pin G) and connector (WT).
X105 (pin 4). Open circuit between cab roof
9), circuit 251 (BL) and right-hand
power mirror connector X105 (pin
4), circuit 251 (BL).
2 Disconnect the cab roof printed Less than 1 ohm. Open circuit between power mirror
circuit connector X129. If good reading, continue with next switch connector S62 (pin G), circuit
Measure the resistance between step. 246 (WT) and cab roof printed circuit
connector S62 (pin G) and connector connector X129 (pin 2), circuit 246
X129 (pin 2). (WT).
3 Disconnect the cab roof printed Less than 1 ohm. Open circuit between cab roof
circuit connector X130. If good reading, continue with next printed circuit connector X130 (pin
Measure the resistance between step. 9), circuit 251 (WT) and right-hand
connector X105 (pin 4) and power mirror connector X105 (pin
connector X130 (pin 9). 4), circuit 251 (BL).
4 Remove the mirror control relay Less than 1 ohm. Mirror control relay K30.
K30. If good reading, install a new cab
Check between K30 terminal (pins roof printed circuit.
3 and 4).
5 Measure the resistance between Less than 1 ohm. Mirror control relay K31.
connector S62 (pin E) and connector If good reading, go to test point 9. Open circuit between power mirror
X105 (pin 3). switch connector S62 (pin E), circuit
247 (WT) and cab roof printed circuit
(WT).
Open circuit between cab roof
8), circuit 252 (WT) and right-hand
3), circuit 252 (BR).
6 Disconnect the cab roof printed Less than 1 ohm. Open circuit between power mirror
circuit connector X129. If good reading, continue with next switch connector S62 (pin E), circuit
Measure the resistance between step. 247 (WT) and cab roof printed circuit
connector S62 (pin E) and connector connector X129 (pin 7), circuit 247
X129 (pin 7). (WT).
7 Measure the resistance between Less than 1 ohm. Open circuit between cab roof
connector X105 (pin 3) and If good reading, continue with next printed circuit connector X129 (pin
connector X129 (pin 8). step. 8), circuit 252 (WT) and right-hand
3), circuit 252 (BR).
12142 1 02/07/2004
E.32.A / 4

8 Remove the mirror control relay Less than 1 ohm. Mirror control relay K31.
K31. If good reading, install a new cab
Check between K31 terminal (pins roof printed circuit.
3 and 4).
connector S62 (pin F) and connector If good reading, the right-hand switch connector S62 (pin F), circuit
X105 (pin 1 and 2). power mirror circuits are okay. 245 (WT) and right-hand power
mirror connector X105 (pin 1 and 2),
circuit 245 (GN).
Mirror Interior mirror - Testing (E.32.A.74.03 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Turn the key start "ON". 12 volts. Additional mirror switch S63.
Disconnect the cab roof printed If good reading, go to test point 3. Open circuit between additional
circuit connector X129. mirror switch S63 connector (pin
Select additional mirror switch to 3) and cab roof printed circuit
German mirror. connector X129 (pin 3), circuit 024
Check for 12 volts at connector (WT).
X129 (pin 3), circuit 024 (WT). Go to next test point.
2 Disconnect the additional mirror Less than 1 ohm. Open circuit between additional
switch S63. If good reading, install a new mirror switch S63 connector (pin
Measure the resistance between additional mirror switch. 3) and cab roof printed circuit
connector S63 (pin 3) and connector connector X129 (pin 3), circuit 024
X129 (pin 3), circuit 024 (WT). (WT).
3 Disconnect the additional power Less than 1 ohm. Open circuit between additional
mirror connector X106. If good reading, continue with next power mirror connector X106 (pin
Measure the resistance between step. B), circuit 254 (ZW) and cab roof
connector X106 (pin B) and printed circuit connector X129 (pin
connector X129 (pin 4). 4), circuit 254 (WT).
4 Measure the resistance between Less than 1 ohm. Open circuit between additional
connector X106 (pin C) and If good reading, continue with next power mirror connector X106 (pin
connector X129 (pin 1). step. C) and cab roof printed circuit
(WT).
5 Disconnect the power mirror switch Less than 1 ohm. Open circuit between additional
connector S62. If good reading, install a new cab power mirror connector X106 (pin
Measure the resistance between roof printed circuit. B), circuit 254 (ZW) and power
connector X106 (pin A) and mirror switch connector S62 (pin F),
connector S62 (pin F). circuit 245 (GN).
12142 1 02/07/2004
E.32.A / 5
Mirror Fuse - Testing (E.32.A.74.80 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the power mirror switch 12 volts. Blown fuse #34.
connector S62. If good reading, continue with next Open circuit between power mirror
Turn the key start "ON". step. switch connector (pin A) and cab
Check for 12 volts at the power roof printed circuit connector X128,
mirror switch connector (pin A). circuit 285 (OR).
2 Turn the key start "OFF". Less than 1 ohm. Open circuit between power mirror
Check for a ground at the power If good reading, the power mirror switch connector (pin H), circuit 435
mirror switch connector (pin H). switch power and ground circuit(s) (ZW) and ground.
are okay.
Mirror Switch - Testing (E.32.A.74.83 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Remove the power mirror switch Less than 1 ohm. Power mirror switch.
S62. If good reading, continue with next
Select the right-hand side mirror. step.
Place the power mirror switch in the
"UP" position.
Measure between power mirror
switch component side terminals:
(pin H and F).
(pin A and E).
2 Place the power mirror switch in the Less than 1 ohm. Power mirror switch.
"DOWN" position. If good reading, continue with next
Measure between power mirror step.
(pin H and E).
(pin A and F).
12142 1 02/07/2004
E.32.A / 6

"LEFT" position. If good reading, continue with next
(pin H and G).
(pin A and F).
"RIGHT" position. If good reading, continue with next
(pin H and F).
(pin A and G).
5 Select the left-hand side mirror. Less than 1 ohm. Power mirror switch.
Place the power mirror switch in the If good reading, continue with next
"UP" position. step.
Measure between power mirror
(pin H and C).
(pin A and D).
"DOWN" position. If good reading, continue with next
(pin H and D).
(pin A and C).
"LEFT" position. If good reading, continue with next
(pin H and B).
(pin A and C).
"RIGHT" position. If good reading, the power mirror
Measure between power mirror switch is okay.
(pin H and C).
(pin A and B).
12142 1 02/07/2004
E.32.A / 7
Mirror - Problem solving (E.32.A.74 - G.40.A.30)

CS540, CS640, CS520, CS660
OPERATION
There are three mirrors left-hand mirror, right-hand mirror and an additional mirror (German).
There are two switches for power mirrors. The mirror adjust switch can adjust position for left-hand mirror, right-hand
mirror or the additional mirror. This action changes the contacts within the switch. The mirror adjust switch can
be set to power either left-hand mirror or the mirror select switch. The mirror select switch can be set to power
German mirror or right-hand mirror.
Switched power is supplied to the mirror adjust switch through fuse #9 from accessory relay.
Only one mirror can be operated at a time.
There are two motors in each mirror assembly. Power and ground are supplied to the motors through three wires for
each mirror assembly, one wire for each motor and one wire in common, therefore the motors can only be operated
in one mode at a time; up only, down only, in only or out only.
Change in mirror motor direction is accomplished by reversing current flow through the motors.
TROUBLESHOOTING
B. Check fuse #9.
C. Check operation of the accessory 1 relay.
D. The transmission is in neutral or park.
E. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals.
CAUTION
CAUTION

All power mirrors are Power mirror switch. A - Power mirror switch component
inoperative test.Mirror Switch - Testing (E.32.A.74.83
- G.40.A.20)
Circuit(s). B - Power mirror switch power and ground
test.Mirror Fuse - Testing (E.32.A.74.80 -
G.40.A.20)
Left hand power mirror Power mirror switch. A - Power mirror switch component test
inoperative (steps 5-8).Mirror Switch - Testing
(E.32.A.74.83 - G.40.A.20)
Circuit(s). C - Left-hand power mirror circuit
test.Mirror Left hand mirror - Testing
(E.32.A.74.01 - G.40.A.20)
Left-hand power mirror. If tests A and C are okay, install a new
Left-hand power mirror.
Right-hand power mirror Power mirror switch. A - Power mirror switch component test
inoperative (steps 1-4).Mirror Switch - Testing
(E.32.A.74.83 - G.40.A.20)
12142 1 02/07/2004
E.32.A / 8

Mirror control relay K30. D - Right-hand power mirror circuit
Mirror control relay K31. test.Mirror Right hand mirror - Testing
Circuit(s). (E.32.A.74.02 - G.40.A.20)
Right-hand power mirror. If tests A and D are okay, install a new
right hand power mirror.
Additional mirror Circuit(s). E - Additional power mirror circuit
inoperative (If fitted) test.Mirror Interior mirror - Testing
(Right-hand power mirror (E.32.A.74.03 - G.40.A.20)
okay)
12142 1 02/07/2004
E.32.A / 9
Index
Mirror - Problem solving (E.32.A.74 - G.40.A.30) 8

CS540, CS640, CS520, CS660
Mirror Fuse - Testing (E.32.A.74.80 - G.40.A.20) 6
CS540, CS640, CS520, CS660
Mirror Interior mirror - Testing (E.32.A.74.03 - G.40.A.20) 5
CS540, CS640, CS520, CS660
Mirror Left hand mirror - Testing (E.32.A.74.01 - G.40.A.20) 3
CS540, CS640, CS520, CS660
Mirror Right hand mirror - Testing (E.32.A.74.02 - G.40.A.20) 3
CS540, CS640, CS520, CS660
Mirror Switch - Testing (E.32.A.74.83 - G.40.A.20) 6
CS540, CS640, CS520, CS660
12142 1 02/07/2004
E.32.A / 10
USER PLATFORM - 34.A
CS540
CS640
CS520
CS660
12143 1 02/07/2004
E.34.A / 1
Contents
DIAGNOSTIC
Wiper system
Wiper system Motor - Testing (E.34.A.65.01 - G.40.A.20) 3
CS540, CS640, CS520, CS660
Wiper system Switch - Testing (E.34.A.65.02 - G.40.A.20) 3
CS540, CS640, CS520, CS660
Wiper system Relay - Testing (E.34.A.65.03 - G.40.A.20) 4
CS540, CS640, CS520, CS660
Wiper system - Problem solving (E.34.A.65 - G.40.A.30) 6
CS540, CS640, CS520, CS660
Windscreen washer system

Windscreen washer system - Testing (E.34.A.66 - G.40.A.20) 7
CS540, CS640, CS520, CS660
Door, window and windscreen

Door, window and windscreen - Testing (E.34.A.76 - G.40.A.20) 8
CS540, CS640, CS520, CS660
12143 1 02/07/2004
E.34.A / 2
BODY AND STRUCTURE - USER PLATFORM
Wiper system Motor - Testing (E.34.A.65.01 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Turn the key start "ON". 12 volts. Open circuit between wiper switch
Place the wiper switch in the "OFF" If good reading, continue with next connector (pin 5B) and cab roof
position. step. printed circuit connector X128 (pin
Check for 12 volts at wiper motor 1), circuit 285 (OR).
connector X109 (pin 5). Open circuit between wiper switch
connector (pin 4) and wiper motor
2 Place the wiper switch in the 12 volts. Open circuit between wiper switch
"INTERMITTENT" position. If good reading, continue with next connector (pin 2B) and cab roof
Check for 12 volts at connector step. printed circuit connector X128 (pin
X109 (pin 5) and (pin 4). 7), circuit 267 (OR).
Open circuit between wiper switch
connector (pin 3) and wiper motor
Open in circuit 285 (OR).
3 Place the wiper switch in the "ON" 12 volts. Open circuit between wiper switch
(continuous) position. If good reading, continue with next connector (pin 6) and cab roof
Check for 12 volts at connector step. printed circuit connector X128 (pin
X109 (pin 4) and (pin 3). 9), circuit 025 (OR).
Open circuit between cab roof
8) and Wiper Motor connector X109
(pin 3).
Open in circuit 267 (OR).
4 Turn the key start "OFF". Less than 1 ohm. Open circuit between wiper motor
Check for a ground at connector If good reading, the wiper motor connector X109 (pin 1) and ground.
X109 (pin 1). circuit(s) are okay.
Wiper system Switch - Testing (E.34.A.65.02 - G.40.A.20)

CS540, CS640, CS520, CS660
12143 1 02/07/2004
E.34.A / 3
CAUTION
WARNING

1 Disconnect the wiper switch Less than 1 ohm. Wiper switch.
connector. If good reading, continue with next
Place the wiper switch in the "OFF" step.
position.
Measure between the wiper switch
connector (pin 5B and 4) component
side.
2 Measure between the wiper switch Open circuit. Wiper switch.
connector (pin 5B and 6) and (pin If good reading, continue with next
2B and 3) component side. step.
3 Place the wiper switch in the Less than 1 ohm. Wiper switch.
"INTERMITTENT" position. If good reading, continue with next
Measure between the wiper switch step.
connector (pin 2B and 3) and (pin
5B and 4) component side.
connector (pin 2B and 1) and (pin If good reading, continue with next
5B and 6) component side. step.
5 Place the wiper switch in the "ON" Less than 1 ohm. Wiper switch.
(continuous) position. If good reading, continue with next
Measure between the wiper switch step.
connector (pin 2B and 3) and (pin
5B and 6) component side.
connector (pin 2B and 1) and (pin If good reading, the wiper switch is
5B and 4) component side. okay.
Wiper system Relay - Testing (E.34.A.65.03 - G.40.A.20)

CS540, CS640, CS520, CS660
12143 1 02/07/2004
E.34.A / 4
CAUTION
WARNING

1 Turn the key start "ON". 12 volts. Blown fuse #34.
Remove the wiper motor relay K43. If good reading, continue with next Open circuit in cab roof printed
Check for 12 volts at wiper motor step. circuit.
relay terminal (pin 3).
2 Turn the key start "OFF". Less than 1 ohm. Open circuit in cab roof printed
Check for a ground at wiper motor If good reading, continue with next circuit.
relay terminal (pin 1). step.
3 Disconnect the cab roof printed 12 volts. Open circuit in cab roof printed
circuit connector X128. Turn the key If good reading, continue with next circuit.
start "ON". step.
Check for 12 volts at X128 (pin 7).
4 Turn the key start "OFF". Less than 1 ohm. Open circuit in cab roof printed
Measure between the following: If good reading, the wiper relay circuit.
wiper relay terminal (pin 5) and circuit(s) are okay.
X128 (pin 8).
wiper relay terminal (pin 2) and
X128 (pin 9).
12143 1 02/07/2004
E.34.A / 5
Wiper system - Problem solving (E.34.A.65 - G.40.A.30)

CS540, CS640, CS520, CS660
OPERATION
The wiper/washer system consists of a two speed motor and a separate washer motor and reservoir.
The system is energized by switched power and will operate in continuous or fixed interval speeds.
TROUBLESHOOTING
Before troubleshooting the wiper/washer system make sure that the following operating conditions are met:
C. Check all connectors for full installation, loose, corroded or pushed out terminals.
D. Check fuse #34.
E. Check power distribution section if fuse and circuit breaker are good.
CAUTION
CAUTION

Wiper motor is inoperative Fuse #34. A - Wiper motor relay circuit test.Wiper
Cab roof printed circuit. system Relay - Testing (E.34.A.65.03 -
G.40.A.20)
Wiper motor relay If test A is okay, install a new wiper motor
relay.
Wiper switch. B - Wiper switch component test.Wiper
system Switch - Testing (E.34.A.65.02 -
G.40.A.20)
Wiper motor circuit(s). C - Wiper motor circuit test.Wiper
system Motor - Testing (E.34.A.65.01 -
G.40.A.20)
Wiper motor. If test C is okay, install a new wiper motor.
Wiper motor works in low Cab roof printed circuit. A - Wiper motor relay circuit test.Wiper
speed only system Relay - Testing (E.34.A.65.03 -
G.40.A.20)
Wiper motor relay If test A is okay, install a new wiper motor
relay.
Wiper switch. B - Wiper switch component test.Wiper
system Switch - Testing (E.34.A.65.02 -
G.40.A.20)
G.40.A.20)
12143 1 02/07/2004
E.34.A / 6

Wiper motor works in high Wiper switch. B - Wiper switch test.Wiper system
speed only Switch - Testing (E.34.A.65.02 -
G.40.A.20)
G.40.A.20)
Wiper motor does not Wiper motor. Install a new wiper motor.
park, stops when switch
is turned OFF
Windscreen washer Washer fluid level low. Check reservoir and fluid lines.
inoperative Blockage in washer lines.
Washer switch. D - Washer switch and motor
Circuit(s). test.Windscreen washer system -
Testing (E.34.A.66 - G.40.A.20)
Washer pump. If test D is okay, install a new washer
pump.
Windscreen washer system - Testing (E.34.A.66 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the washer switch 12 volts. Open circuit between washer switch
connector. If good reading, continue with next connector (pin 2B) and cab roof
Turn the key start "ON". step. printed circuit connector X128 (pin
Check for 12 volts at washer switch 1), circuit 285 (OR).
connector (pin 2B).
2 Turn the key start "OFF". Less than 1 ohm. Washer switch.
Place the washer switch in the "ON" If good reading, continue with next
position. step.
Measure between the washer switch
connector (pin 2B and 3) component
side.
3 Disconnect the washer pump Less than 1 ohm. Open circuit between the washer
connector. If good reading, continue with next switch connector (pin 3) and the
Measure between the washer switch step. washer pump connector (pin 1),
connector (pin 3) and the washer circuit 239 (WT).
pump connector (pin 1).
4 Measure between the washer pump Less than 1 ohm. Open circuit between the washer
connector (pin 2) and ground. If good reading, the washer switch pump connector (pin 2) and ground,
and circuit(s) are okay. circuit 128 (ZW).
12143 1 02/07/2004
E.34.A / 7
Door, window and windscreen - Testing (E.34.A.76 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the interior light Less than 1 ohm. Door switch.
connector (pin 1) (BL). Open the If good reading, install a new interior Open in circuit 284 (BL).
cab door. light. Go to next test point.
Check for a ground at the interior
light connector (pin 1), circuit 284
(BL).
2 Disconnect the door switch S57 Less than 1 ohm. Open circuit between interior light
connector. If good reading, install a new Door connector (pin 1), circuit 284 (BL)
Measure resistance between the Switch. and the door switch connector.
door switch connector and the
interior light connector (pin 1), circuit
284 (BL).
12143 1 02/07/2004
E.34.A / 8
Index
Door, window and windscreen - Testing (E.34.A.76 - G.40.A.20) 8

CS540, CS640, CS520, CS660
Windscreen washer system - Testing (E.34.A.66 - G.40.A.20) 7
CS540, CS640, CS520, CS660
Wiper system - Problem solving (E.34.A.65 - G.40.A.30) 6
CS540, CS640, CS520, CS660
Wiper system Motor - Testing (E.34.A.65.01 - G.40.A.20) 3
CS540, CS640, CS520, CS660
Wiper system Relay - Testing (E.34.A.65.03 - G.40.A.20) 4
CS540, CS640, CS520, CS660
Wiper system Switch - Testing (E.34.A.65.02 - G.40.A.20) 3
CS540, CS640, CS520, CS660
12143 1 02/07/2004
E.34.A / 9
12143 1 02/07/2004
E.34.A / 10
ENVIRONMENT CONTROL Heating system - 40.B
CS540
CS640
CS520
CS660
12144 1 02/07/2004
E.40.B / 1
Contents
SERVICE
ENVIRONMENT CONTROL Heating system - Check (E.40.B - F.45.A.10) 3

CS540, CS640, CS520, CS660
12144 1 02/07/2004
E.40.B / 2
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating system
ENVIRONMENT CONTROL Heating system - Check (E.40.B -

F.45.A.10)
CS540, CS640, CS520, CS660
1. Check that both engine coolant shutoff valves at the

engine block are open.
(CCW = Open, CW = Closed)
2. Check that the heater supply hose at the rear of
the engine head is warm.
3. Check that the engine coolant temperature is at
least 76 ° C (170 ° F).
4. Check the cab fresh air filter to check that it is clean
and free from obstruction to air flow.
5. Check the cab recirculation air filter to see that it is
clean and free from obstruction to air flow.
20018348 1
1 Supply to cab 2 Return from cab
12144 1 02/07/2004
E.40.B / 3
Index
ENVIRONMENT CONTROL Heating system - Check (E.40.B - F.45.A.10) 3

CS540, CS640, CS520, CS660
12144 1 02/07/2004
E.40.B / 4
ENVIRONMENT CONTROL Air-conditioning system - 40.C
CS540
CS640
CS520
CS660
12145 1 02/07/2004
E.40.C / 1
Contents
TECHNICAL DATA
ENVIRONMENT CONTROL Air-conditioning system - Special tools (E.40.C - D.20.A.40) 5

CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - General specification (E.40.C 5
- D.40.A.10)
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - General specification (E.40.C 5
- D.40.A.10)
CS540, CS640, CS520, CS660
Compressor
Compressor - General specification (E.40.C.31 - D.40.A.10) 5
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
ENVIRONMENT CONTROL Air-conditioning system - Functional diagram (E.40.C 7

- C.20.A.70)
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - A/C schema (E.40.C - C.20.B.35) 8
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Static description (E.40.C - 9
C.30.A.20)
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Dynamic description (E.40.C 10
- C.30.A.10)
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Component localisation (E.40.C 11
- C.40.B.20)
CS540, CS640, CS520, CS660
Command
Command - Static description (E.40.C.05 - C.30.A.20) 12
CS540, CS640, CS520, CS660
Compressor
Compressor - Static description (E.40.C.31 - C.30.A.20) 13
CS540, CS640, CS520, CS660
Condenser
Condenser - Static description (E.40.C.32 - C.30.A.20) 14
CS540, CS640, CS520, CS660
Receiver/drier
Receiver/drier - Static description (E.40.C.35 - C.30.A.20) 15
CS540, CS640, CS520, CS660
Sensing system
12145 1 02/07/2004
E.40.C / 2
Sensing system - Dynamic description (E.40.C.95 - C.30.A.10) 16
CS540, CS640, CS520, CS660
Sensing system Limit switch - Static description (E.40.C.95.85 - C.30.A.20) 27
CS540, CS640, CS520, CS660
SERVICE
ENVIRONMENT CONTROL Air-conditioning system - Service instruction (E.40.C - 28

F.10.A.05)
CS540, CS640, CS520, CS660
F.10.A.05)
CS540, CS640, CS520, CS660
F.10.A.05)
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Cleaning (E.40.C - F.30.A.10) 32
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Storing (E.40.C - F.35.A.02) 33
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Drain fluid (E.40.C - F.35.A.20) 34
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Pre delivery inspection (E.40.C - 36
F.40.A.15)
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Preliminary test (E.40.C - F.40.A.20) 37
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Tool description (E.40.C - F.40.D.20) 38
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Tool usage (E.40.C - F.40.D.22) 39
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Check (E.40.C - F.45.A.10) 41
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Charging (E.40.C - F.60.A.30) 43
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Filling (E.40.C - F.60.A.10) 44
CS540, CS640, CS520, CS660
Compressor
Compressor - Remove (E.40.C.31 - F.10.A.10) 45
CS540, CS640, CS520, CS660
Compressor - Install (E.40.C.31 - F.10.A.15) 46
CS540, CS640, CS520, CS660
Compressor Magnetic clutch - Remove (E.40.C.31.80 - F.10.A.10) 47
CS540, CS640, CS520, CS660
Compressor Magnetic clutch - Install (E.40.C.31.80 - F.10.A.15) 50
CS540, CS640, CS520, CS660
Condenser
Condenser - Remove (E.40.C.32 - F.10.A.10) 52
CS540, CS640, CS520, CS660
Condenser - Install (E.40.C.32 - F.10.A.15) 53
CS540, CS640, CS520, CS660
Receiver/drier
12145 1 02/07/2004
E.40.C / 3
Receiver/drier - Remove (E.40.C.35 - F.10.A.10) 54
CS540, CS640, CS520, CS660
Receiver/drier - Install (E.40.C.35 - F.10.A.15) 55
CS540, CS640, CS520, CS660
Sensing system
Sensing system Limit switch - Remove (E.40.C.95.85 - F.10.A.10) 56
CS540, CS640, CS520, CS660
Sensing system Limit switch - Install (E.40.C.95.85 - F.10.A.15) 57
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
DIAGNOSTIC
ENVIRONMENT CONTROL Air-conditioning system - Troubleshooting (E.40.C - 60

G.40.A.10)
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Troubleshooting (E.40.C - 61
G.40.A.10)
CS540, CS640, CS520, CS660
12145 1 02/07/2004
E.40.C / 4
BODY AND STRUCTURE - ENVIRONMENT CONTROL Air-conditioning system
ENVIRONMENT CONTROL Air-conditioning system - Special tools

(E.40.C - D.20.A.40)
CS540, CS640, CS520, CS660

Refrigerant gas leak detector 380000314 294036
R-134 Recovery/Recycle and 380000315 294161
recharging station
Thermometer - OEM1662
Service gauge set - 134A - OEM1419
Sanko/Sanden compressor tools 380000333 297422
ENVIRONMENT CONTROL Air-conditioning system - General

specification (E.40.C - D.40.A.10)
CS540, CS640, CS520, CS660
Refrigerant R-134a and the lubricant used with it were developed together. The lubricant is made from Poly
Aklylene Glycol (PAG) and is not compatible with the mineral oil used with R-12 systems. Mixing of R-134a and
mineral oil will cause the oil to become chemically unstable, attacking internal components. Hoses, bearing shaft
seals and O-rings designed for R-12 systems cannot be used in air conditioning systems with R-134a refrigerant.
Hardening, swelling or cracking of these parts will occur. The recommended lubricant to be used in the combine
A/C system is PAG SP-10.
The lubricants used with R-134a systems are far more aggressive to rubber parts than the mineral oils used with
other systems. When servicing this A/C system, be certain that the rubber parts you are installing is approved
for use with R-134a and its oil.
ENVIRONMENT CONTROL Air-conditioning system - General

specification (E.40.C - D.40.A.10)
CS540, CS640, CS520, CS660
Applicable SAE standards:

J639 Safety and containment of refrigerant for mechanical vapor compression systems
used for mobile air conditioning systems.
J1989 Recommended service procedure for the containment of R-12.
J1991 Standard of purity for use in mobile air conditioning systems.
J2099 Standard of purity for recycled R-134a for use in a mobile air conditioning system.
J2196 Service hose for automotive air conditioning.
J2197 R-134a service hose fittings for automotive air conditioning service equipment.
J2211 Recommended service procedure for the containment of R -134a.
J2219 Committee draft: Concern to the mobile air conditioning industry.
Related SAE standards:

J1990 Recovery and recycle equipment for mobile air conditioning systems.
J2209 R-12 recovery equipment for mobile air conditioning systems.
J2210 R-134a recycling equipment for mobile air conditioning systems.
Compressor - General specification (E.40.C.31 - D.40.A.10)

CS540, CS640, CS520, CS660
Refrigerant
12145 1 02/07/2004
E.40.C / 5
Specification: R134 a
Amount: 2100 g
Compressor
Type: SANDEN SD7H15KG8143
Displacement per revolution: 154.9 cc
Oil capacity: 360 cc (Sanden SP-10) (135 cc in compressor + 225 cc in circuit)
NOTE: The use of R134a in an automotive air-conditioning compressor requires special attention to lubrication.
A specific PAG - type oil, Sanden SP-10, has been developed to suit the SD7H15. Care must be taken to avoid
incorrect oils being used as SP-10 is the only lubricant approved for use with the SD7H15.
Compressor clutch
Rated voltage: DC 12 V
Break-away torque: 34.3 Nm (25.3 lb ft)
Minimum engagement voltage: 7.5 V
Power consumption: 43 watts
Belt type: 8 multi- V
Circuit parameters
Air-conditioning Ambient temperature °C Low pressure bar High pressure bar

Not in operation 20 4.5 4.5
Not in operation 30 6.5 6.5
In operation 20 0.5 to 1 11
In operation 30 1 14
Low pressure switch
Switch normally open: non adjustable
Cut-in set point: 2.5 bar +/- 0.3 bar
Cut-out set point: 0.3 bar +/- 0.15 bar
Switch body color: bronze
High pressure switch
Switch normally closed: non adjustable
Cut-out set point: 28 bar +/- 1.5 bar
Cut-in set point: 19 bar +/- 1.5 bar
Switch body color: green
12145 1 02/07/2004
E.40.C / 6
ENVIRONMENT CONTROL Air-conditioning system - Functional

diagram (E.40.C - C.20.A.70)
CS540, CS640, CS520, CS660
50_sec50-1_09 1
A/C cycle
12145 1 02/07/2004
E.40.C / 7
ENVIRONMENT CONTROL Air-conditioning system - A/C schema

(E.40.C - C.20.B.35)
CS540, CS640, CS520, CS660
Components
1. Compressor
2. High pressure switch
3. High pressure charge port ("S": Suction port)
4. Condenser
5. Filter-drier
6. Expansion valve
7. Evaporator
8. Low pressure charge port ("D": Discharge port)
9. Low pressure switch
51125 1
12145 1 02/07/2004
E.40.C / 8
ENVIRONMENT CONTROL Air-conditioning system - Static

description (E.40.C - C.30.A.20)
CS540, CS640, CS520, CS660
The refrigerant used is R-134a, a hydro fluoro carbon (HFC) that has no ozone consuming chlorine molecule.
NOTE: Follow all local and governmental regulations regarding the handling of HFC materials before performing any
work on systems using HFC compounds.
CAUTION
Z026 - This air-conditioning system uses R-134a refrigerant. Use only R-134a refrigerant and compatible
lubricants in this system. Gases and lubricants of R-134a and R-12 are not compatible with each other,
they must be handled separately and not mixed.
Vehicles with R-134a system components are distinguished from others that use R-12 by an ID tag mounted on or
near the compressor mounting location.
The function of the climate control system is to provide a comfortable environment for the operator by raising or
lowering the air temperature, reducing the humidity level and removing dust and pollen within the cab compartment.
Using the control panel, the operator controls fan speed, heater valve position and compressor operation by
direct input.
The components of the climate control system are located at various points on the combine. The control panel (1) is
in the headliner of the operators’ cab. In the roof of the cab is the central air handling (2) unit which houses the blower
fan, heater core, evaporator core and water valve. A separator fan (3) is located behind the shielding outside the left
cab door. The compressor, condenser and filter-drier are mounted in and around the engine compartment at (4).
ZDF0902A 1
12145 1 02/07/2004
E.40.C / 9
ENVIRONMENT CONTROL Air-conditioning system - Dynamic

description (E.40.C - C.30.A.10)
CS540, CS640, CS520, CS660
NOTE: Refer to ENVIRONMENT CONTROL Air-conditioning system - Functional diagram (E.40.C - C.20.A.70)
Refrigerant is drawn into the compressor as a cool, low-pressure vapor, compressed and then moves out as a
hot, high-pressure vapor to the condenser.
As the hot, high-pressure vapor passes through the condenser core, it gives off heat to the cooler outside air
being drawn past the condenser cooling fins.
The vapor is condensed to a liquid by giving off heat to the outside air. This liquid moves to the filter-drier under
high pressure.
Hot, high-pressure liquid is stored in the filter-drier until it is released to the evaporator by the expansion valve.
The liquid refrigerant passes through a metered orifice in the expansion valve and into the evaporator coil. As the
refrigerant passes through the orifice in the expansion valve, the refrigerant changes from a high-pressure liquid
to a low-pressure atomized liquid. Then, when it reaches the evaporator coils, it begins to cool, absorbing heat
from the air drawn across the coils and fins by the blower. The refrigerant now changes from a cold low-pressure
liquid to a cool low-pressure vapor and leaves the evaporator outlet moving to the suction (low-pressure) side of the
compressor to repeat the cycle.
As the heat loss is taking place, moisture (humidity) in the air will condense on the outside of the evaporator and
drain off as water through the drain hoses attached to the evaporator drain pan, thereby reducing the humidity level
of the cab. Also, dust or pollen not removed by the cab filters will collect on the wet evaporator fins and coils and
may require periodic cleaning depending on operating conditions.
In summary, the heat in the cab is removed by the refrigerant in the evaporator and is transferred from the refrigerant
to the outside air by the condenser unit.
12145 1 02/07/2004
E.40.C / 10
ENVIRONMENT CONTROL Air-conditioning system - Component

localisation (E.40.C - C.40.B.20)
CS540, CS640, CS520, CS660
Filter-drier (5)
ZDA6254C 1
Condenser (4)
ZDA5954C 2
Compressor (1)
High pressure switch (2)
High pressure charge port (3) "D": Discharge port
Low pressure charge port (8) "S": Suction port
Low pressure switch (9)
ZEIL04CS0105A0B 3
Evaporator (7)
ZEIL04CS0104A0B 4
12145 1 02/07/2004
E.40.C / 11
Command - Static description (E.40.C.05 - C.30.A.20)

CS540, CS640, CS520, CS660
The control panel operates the various modes of the cab climate control system.
The fan switch (1) is a four position switch used to select Off "0", Low "1", Medium "2", and High "3" fan speeds. No
other speed control is provided.
The temperature control knob (2), gives the operator control over the amount of heated engine coolant that will
circulate through the heater core. If a warmer air temperature is desired, rotate the knob clockwise. With the control
knob in the fully clockwise position, the water valve is completely open allowing maximum coolant flow through the
core, and maximum heating of the cab air.
The A/C button (3), when pressed, will energize the air conditioning circuit causing the A/C compressor to cycle
according to its own control parameters. A light (4) above the switch illuminates to indicate the air conditioning
system is operating.
ZEIL04CS0103A0B 1
12145 1 02/07/2004
E.40.C / 12
Compressor - Static description (E.40.C.31 - C.30.A.20)

CS540, CS640, CS520, CS660
The compressor, mounted inside the engine compartment, is driven by the crankshaft pulley. Refrigerant and oil is
moved through the air conditioning system by the compressor, which lubricates and cools the unit during operation.
An electromagnetic clutch is used to engage or disengage the compressor as required when operating the
air-conditioning system. The clutch is of a stationary coil type and forms an integral part of the compressor pulley
assembly. When the coil is energized, the clutch plate is pulled against the rotating pulley. De-energizing the
coil will allow the plate to return to a standby position.
50_sec50-2_01 1
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Condenser - Static description (E.40.C.32 - C.30.A.20)

CS540, CS640, CS520, CS660
The condenser (1) is located on the inside of the screen cleaner swing out door. The condenser consists of a
number of turns of continuous coil mounted in a series of thin cooling fins to provide maximum heat transfer
in a minimum amount of space.
The condenser receives the hot, high-pressure refrigerant vapor from the compressor. As the hot vapor passes
through the coils, outside air is drawn around the coils by the engine fan. Heat is transferred from the hot refrigerant
vapor into the cooler outside air flowing across the coils and fins. The refrigerant condenses inside the unit and
becomes a high pressure liquid.
ZDA5954B 1
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Receiver/drier - Static description (E.40.C.35 - C.30.A.20)

CS540, CS640, CS520, CS660
The filter-drier (5), located on the right-hand side of the engine compartment is a storage tank that receives the
high-pressure liquid refrigerant from the condenser through an inlet line.
The refrigerant exits the filter-drier (5) through an outlet connection and flows to the thermostatic expansion valve.
ZDA6254C_100 1
A sight glass (3) and a ring shaped moisture indicator (4) is installed so that the general condition of the refrigerant
charge can be determined. The decision to add refrigerant should not be based on the indication of the sight glass
alone. Perform the appropriate steps of the ENVIRONMENT CONTROL Air-conditioning system - Service
instruction (E.40.C - F.10.A.05) section.
NOTE: Any moisture in the air-conditioning system is extremely harmful. Moisture not absorbed by the filter-drier
will circulate with the refrigerant. Droplets may collect and freeze in the thermostatic expansion valve restricting
refrigerant flow. The moisture circulating in the system may also react with the refrigerant to form hydrochloric acid.
NOTE: In general, the filter-drier (5) should be replaced any time the system is opened for service.
ZDA6254A 2
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Sensing system - Dynamic description (E.40.C.95 - C.30.A.10)

CS540, CS640, CS520, CS660
50_sec50-1_13 1
1 Low side low 2 High side low

3 High side hand valve closed 4 High side hose connected to high side service connector
5 Not used 6 Low side hose connected to low side service connector
7 Low side hand valve closed
GAUGE READINGS AND INTERPRETATIONS
EXAMPLE 1
Problem:
Little or no cooling.
Cause:
Refrigerant slightly low.
CONDITIONS*
1. Low side pressure too low.

2. High side pressure too low.
3. Evaporator air not cold.
CORRECTIVE PROCEDURES
1. Leak test the system.

2. Repair leaks. (Discharge and recover the refrigerant from the system; replace lines or components).
3. Replace any oil lost during recovery with new oil. Be sure to use oil compatible with the system.
4. Evacuate the system.
5. Charge the system.
6. Performance test the system.
NOTE: DIAGNOSIS: System refrigerant is low. May be caused by a small leak.
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50_sec50-1_14 2

EXAMPLE 2
Problem:
Insufficient cooling.
Cause:
Refrigerant excessively low.
CONDITIONS*
1. Low side pressure very low.

3. Evaporator air warm.
Corrective procedures
1. Leak test the system.

2. Recover the refrigerant from the system.
3. Repair leaks.
4. Replace any oil lost during recovery with new oil. Be sure to use oil compatible with the system.
NOTE: DIAGNOSIS: System refrigerant is extremely low. A serious leak is indicated.
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50_sec50-1_15 3
1 Low side low 2 High side normal

EXAMPLE 3
Problem:
Cause:
Air in system.
CONDITIONS*
1. Low side pressure reading does not change when compressor cycles “on" and “off."
2. High side pressure slightly high or slightly low.
1. Leak test the system. Give special attention to the compressor seal area.
3. Repair leaks.
4. Replace the filter-drier.
5. Check compressor oil to ensure no loss.
NOTE: DIAGNOSIS: Non-condensables (air or moisture) present. System not fully charged.
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50_sec50-1_16 4
1 Low side high 2 High side low

EXAMPLE 4
Problem:
Cause:
Compressor malfunction.
CONDITIONS*
1. Low side pressure too high.

3. System fully charged
1. Replace the compressor.

NOTE: DIAGNOSIS: Internal leak in compressor caused by worn or scored pistons, rings, or cylinders.
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50_sec50-1_17 5
1 Low side high 2 High side high

EXAMPLE 5
Problem:
Insufficient or no cooling. Engine overheats in some cases.
Cause:
Condenser not functioning properly.
CONDITIONS*

2. High side pressure too high.
3. Liquid line hot.
1. Check belt tension. Loose or worn drive belts could cause excessive pressures in the compressor head.
2. Look for clogged passages between the condenser fins and coil, or other obstructions that could reduce
condenser air flow.
3. If engine overheating is a symptom, check radiator fan and pressure cap for proper operation.
(At this point, operate the system and check its performance. If still unsatisfactory, proceed as follows.)
4. Check for overcharge of refrigerant, and correct as follows:
Discharge and recover the refrigerant.
Add new refrigerant.
(Operate the system and re-check the performance. If the gauge readings are still too high, proceed as follows.)
6. Remove the condenser; if it appears dirty or plugged, replace it.
8. Evacuate the system, and recharge it.
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NOTE: DIAGNOSIS: Lack of cooling caused by pressure that is too high on the high side, resulting from improper
operation of condenser. (Refrigerant charge may be normal or excessive.)
50_sec50-1_18 6
1 Low side normal 2 High side normal

EXAMPLE 6
Problem:
Insufficient cooling during hottest part of hot days.
Cause:
Moisture in the system.
CONDITIONS*
1. Low side pressure reading normal but drops to a vacuum reading during testing.
2. High side pressure reading normal but drops when low side reading shows a vacuum.
3. Evaporator air sufficiently cold until low side pressure gauge shows a vacuum, then it becomes warm.

NOTE: DIAGNOSIS: Excessive moisture in system. Drying agent in filter-drier is saturated and releases moisture
during high outside air temps. This moisture collects and freezes in the expansion valve, preventing a flow of
refrigerant through the evaporator.
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50_sec50-1_19 7
1 Low side normal 2 High side normal

EXAMPLE 7
Problem:
Insufficient or no cooling.
Cause:
Large amount of air in system.
CONDITIONS*

3. Evaporator air not cool.

NOTE: DIAGNOSIS: Air in system. This, and the moisture in the air, is contaminating the refrigerant, causing the
system to operate improperly.
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50_sec50-1_20 8
1 Low side high 2 High side high

EXAMPLE 8
Problem:
Insufficient or no cooling.
Cause:
Improper operation of thermostatic expansion valve (stuck open)
CONDITIONS*

4. Evaporator and suction hose (to compressor) surfaces show considerable moisture.
1. Check for sticking expansion valve:

Operate the system at maximum cooling
Check the low side gauge. The pressure should drop slowly.
2. If the test indicates that the expansion valve is defective, proceed as follows:
Recover the refrigerant from the system.
Replace the expansion valve.
Evacuate the system.
Charge the system.
Performance test the system.
NOTE: DIAGNOSIS: Thermostatic expansion valve is allowing too much refrigerant to flow through the evaporator
coils. Valve may be stuck open.
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50_sec50-1_21 9

EXAMPLE 9
Problem:
Cause:
Improper operation of thermostatic expansion valve (stuck closed).
CONDITIONS*
1. Low side pressure too low (0 PSI or vacuum).

2. High side pressure low.
3. Evaporator air cool, but not sufficiently cold.
4. Evaporator valve inlet pipe surface shows considerable moisture or frost.
1. Place finger on expansion valve inlet. If too cold to touch, proceed as follows:
Operate the system at maximum cooling.
Check the low side gauge. The pressure should drop slowly.
2. If the expansion valve inlet surface shows frost or heavy moisture, proceed as follows:Discharge and recover
the refrigerant from the system.
3. If the corrective procedure outlined in Step 1 shows that the expansion valve is defective, proceed as follows:
Charge the system.
Performance test the system.
NOTE: DIAGNOSIS: Expansion valve is not permitting a sufficient flow of refrigerant. May be caused by valve stuck
in restricted or closed position.
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50_sec50-1_22 10

EXAMPLE 10
Problem:
Cause:
Restriction in high side of system.
CONDITIONS*
1. Low side pressure too low.

3. Evaporator only slightly cool.
4. Liquid line and filter-drier are cool to touch and show frost or considerable moisture.
NOTE: A normal or high reading of the high side pressure gauge under these conditions indicates the system is
overcharged or the condenser is restricted.
1. Discharge and recover the refrigerant from the system.

2. Replace the liquid lines, filter-drier, or other obstructed components.
NOTE: DIAGNOSIS: Restriction in the liquid line and/or filter-drier resulting in a “starved" evaporator (compressor
removing refrigerant from the evaporator faster than it can enter).
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50_sec50-1_23 11
1 Low side gauge 2 High side normal

Compressor cycles on at 2.3 bar (33.3 PSI)
Compressor cycles off at 1.9 bar (27.6 PSI)
EXAMPLE 11
Problem:
Compressor cycles (cuts in and out) too rapidly.
Cause:
Thermostatic switch.
CONDITIONS*
1. Low side pressure readings too high during both “on" and “off" compressor cycles and between cycles.
2. High side pressure normal.
1. Stop the engine and shut off air conditioning system.

2. Replace thermostatic switch.
3. Make sure the switch temperature sensing line is installed in the same position and depth (in evaporator
core) as previous bulb.
CAUTION
Z017 - Line is filled with refrigerant under pressure. Do not kink or bend it too sharply.
NOTE: DIAGNOSIS: Defective thermostatic switch.
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Sensing system Limit switch - Static description (E.40.C.95.85 -

C.30.A.20)
CS540, CS640, CS520, CS660
The high pressure cut-out switch (2) monitors the operating pressure on the high pressure side of the A/C system.
The function of this switch is to prevent the compressor from operating when the pressure on the high side exceeds
the preset operating limits. When actuated at 28.96-26.20 bars (420-380 psi) increasing, the electrical contacts in
the switch open and secure power to the compressor clutch. The pressure switch will reset at 20.69-17.93 bars
(300-260 psi) decreasing. The set point is not adjustable.
The low pressure cut-out switch (1) monitors the operating pressure on the low pressure side of the A/C system.
The function of this switch is to prevent the compressor from operating when pressure on the low side is less
than the preset operating limits. When actuated at .070 - .482 bars (1-7 psi) decreasing, the electrical contacts
in the switch open and stop power to the compressor clutch. The pressure switch will reset at 2.134-2.686 bars
(31-39 psi) increasing. The set point is not adjustable.
ZDF0850B 1
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ENVIRONMENT CONTROL Air-conditioning system - Service

instruction (E.40.C - F.10.A.05)
CS540, CS640, CS520, CS660
1. Operate the air-conditioning unit with the engine

on idle speed and the ventilator on position II for at
least five minutes once a month during the storage
period (i.e. to oil all compressor seals and to avoid
leakages).
NOTE: The air-conditioning system must only be
operated if the cab temperature is 21 °C or more. The
air-conditioning system must only be operated if the
ambient temperature is higher than 10 °C.
ATTENTION: It is fully recommended to have the
air-conditioning system checked yearly by a specialist
(before the start of the harvest season).
ATTENTION: After recharging of the system by a
specialist, ensure the engine speed is set at low idle,
then engage and run the air-conditioning system for two
2 minutes to allow the system gas and lubrication to
normalise.
2. After this initial run-up the system can be used
normally.
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CS540, CS640, CS520, CS660
Refrigerants must not be mixed. For this reason, service fittings are different for refrigerants R-12 and R-134a.
Systems using R-134a have quick couple service connections while R-12 systems use screw threads. The intent
of this is to prevent the use of the same tools for different refrigerants, thereby avoiding mixing of refrigerants in
the service equipment.
Incompatible lubricants and other contaminants can be left behind on air conditioning service manifolds, gauges,
hoses and fittings. Even small amounts of refrigerant and lubricant left behind can be harmful to the performance
and durability of a system designed to use another refrigerant.
If refrigerants are mixed, the thermodynamic and chemical characteristics will change resulting in excessive
pressure and poor lubrication, leading to failure of the compressor, desiccant and other system components.
Mixtures of R-12 and R-134a can result in a 25 % over pressure resulting in system failure.
1. To help avoid a mix-up of service equipment and

refrigerants, equipment hoses designed for use
with each refrigerant is easily identified. New
service hoses compatible with R-12 will carry the
designation "SAE J2196". Service hoses used
with R-134a must have a black stripe along the
entire hose length and carry the designation "SAE J
2196/R-134a."
12145 1 02/07/2004
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CS540, CS640, CS520, CS660
WARNING
Z005 - Be sure to use the correct and dedicated equipment for testing and working on any system
containing R-134a. Read and understand all of the following information before working on this system.
CAUTION
Z003 - Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, and
throat. To remove R-134a from the A/C system, use service equipment certified to meet the requirements
of SAE J2210 (R-134a recycling equipment). If accidental system discharge occurs, ventilate the work
area before resuming service. Additional health and safety information may be obtained from refrigerant
and lubricant manufacturers.
General safety and service precautions

All refrigerants have potentially dangerous physical and chemical properties. Refrigerants are stored under
relatively high pressure as a liquid, and all of them are chemicals which can be harmful or fatal if not treated
properly. When not used as directed, you could be exposed to physical injury, frostbite, blindness, poisoning, death
by asphyxiation, or cardiac arrest. In addition, some of the new refrigerants including R-134a have been found
to be flammable under certain conditions.
1. Read, understand, and follow the instructions

provided by the manufacturer of all the service
equipment that you will be working with.
2. Wear safety goggles at all times when servicing
an air conditioning system, extraction recycling
equipment, or otherwise handling refrigerant. Liquid
splashed in the eye can cause frostbite and/or
irritation.
Wear appropriate rubber gloves and other protective
clothing. Extreme care should be used when
handling R-134a in order to prevent contact with
skin and other body parts. This is to prevent
freezing of body tissues. Liquid R-134a boils at -18
- -11 ° C (0 - 12 ° F) at atmospheric pressure. Read
and follow the information in the material safety
data sheet provided by your refrigerant supplier
regarding the proper handling of refrigerant.
3. Never mix R-134a with air for leak testing. In
general, it should not be used or allowed to be
present with high concentrations of air above
atmospheric pressure. It has been determined that
pressurized, air rich mixtures of R-134a can undergo
combustion when exposed to an ignition source.
4. Never perform operations other than routine
maintenance on your extraction or recycling
equipment without first consulting the
manufacturers’ authorized personnel. Removal
of fittings and filters can cause refrigerant under
pressure to escape. Use the proper safety
equipment, including safety goggles.
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5. Never service or maintain extraction or recycling

equipment while it is plugged in unless proper
service procedures direct you to do so.
6. Always transfer refrigerant to cylinders or tanks
specifically approved for refilling. Use no other
containers.
7. Never overfill a refrigerant container. There must
be a vapor space left in the cylinder in order to
accommodate temperature-induced changes in
pressure and liquid volume. SAE recommends
filling tanks for shop use with liquid to no more than
60 % of their gross weight rating.
8. Ensure that containers are never heated to over
52 ° C (125 ° F). Even a correctly filled container
becomes an explosive hazard if its temperature
exceeds 52 ° C (125 ° F).
9. Recycling equipment may create sparks or arcs
in internal switches or other systems. Because of
the fire and explosive hazard that may be present,
always use recycling equipment in locations with
forced ventilation having at least four air changes
per hour.
10. Extension cords are a known cause of fires
and equipment malfunction. Their use is not
recommended. In circumstances where their use
is unavoidable, the shortest cord with 14 gauge or
larger conductors must be used. If your service
equipment requires a ground circuit (third prong),
make sure that the extension cord is so equipped
and that the ground circuit is intact. Avoid cords that
are worn, frayed, or otherwise damaged.
11. Perform work in well-ventilated areas. Refrigerants
accumulate in low areas such as service pits.
Breathing concentrated refrigerant vapors could
result in asphyxiation or other health hazards,
including cardiac arrest.
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ENVIRONMENT CONTROL Air-conditioning system - Cleaning

(E.40.C - F.30.A.10)
CS540, CS640, CS520, CS660
° CLEANING
Many failures in all types of systems can be traced to dirt. The cleaner your work, the longer the systems will last, and
the less need there will be for maintenance operations that could potentially release refrigerant into the atmosphere.
Dirt, even microscopic particles, in hose connections can create enough clearance for the refrigerant to escape.
° FLUSHING
Flushing the system is not recommended. In the event of a major compressor failure replacing the compressor
output pressure line and filter-drier should collect most of the debris.
Some service or repair operations have been flushing A/C systems to remove dirt or other debris. It has been
common practice to use another CFC (ChloroFluoroCarbons), usually R-11, for this purpose. The use of any
CFC for such a purpose is prohibited where the CFC may be released into the atmosphere. Methychloroform, a
popular flushing agent, is also prohibited.
CAUTION
Z012 - Flushing should never be done with shop or other compressed air. Certain mixtures of air and R-134a
are combustible. The use of air to flush R-134a systems could result in combustion. Shop air also contains
moisture which would contaminate the system.
IMPORTANT: Never use CFC-11, R-11, CFC-12, R-12, CFC-113, R-13 or any substance to flush an R-134a system.
To do so would result in breakdown of the lubricant and system corrosion.
1. Use of other flushing solvents may cause other
problems. If a vacuum pump does not remove the
solvent, it could affect the chemical stability of the
refrigerant and lubricant.
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ENVIRONMENT CONTROL Air-conditioning system - Storing

(E.40.C - F.35.A.02)
CS540, CS640, CS520, CS660
Recycled refrigerant must be stored only in DOT CFR Title 49 or UL containers approved for such use. The
container must be specifically marked for the refrigerant type you are storing. The use of unmarked containers must
be avoided as it can lead to mixing of refrigerants and consequent A/C system failure.
Disposable refrigerant containers should not be used for the storage or recovery of used or recycled refrigerant.
Disposable containers are the type of containers in which virgin refrigerant is often sold.
Any container of recycled refrigerant that has been stored or transferred must be checked prior to its use in
accordance with the temperature/pressure check described in ENVIRONMENT CONTROL Air-conditioning
system - Tool usage (E.40.C - F.40.D.22).
New storage tanks must be evacuated to at least 635 mm (25 in) of mercury prior to use. Otherwise, excess
air may be introduced to the refrigerant.
Transfer of refrigerant
To transfer refrigerant in portable containers, you must make sure that:
1. The container meets DOT CFR Title 49 requirements and is UL-approved for such use.
2. The container is free of contaminants and air.
3. Container filling operations are controlled by weight. In the shop, containers must be filled NO MORE THAN
60 % of their gross weight rating. This will prevent overfilling and possible explosion if the container is exposed
to higher temperatures.
Disposal of empty or near empty disposable containers
Improper scrapping of disposable containers can release some refrigerant into the atmosphere. This must be
avoided by removing any of the remaining contents with a recovers or recycling machine as follows.
1. Attach the service hose of your recovery or recycling

machine to the container.
2. Open the container valve and the recovery/recycling
equipment shutoff valve and evacuate the container
just as you would a mobile air conditioning system.
3. When the maximum stable vacuum has been
achieved, close the container valve and the service
hoses valves, allowing the vacuum to be in the
container.
4. Mark the container “empty" and dispose of it
properly.
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ENVIRONMENT CONTROL Air-conditioning system - Drain fluid

(E.40.C - F.35.A.20)
CS540, CS640, CS520, CS660
1. Ensure that all service equipment hose lines are

fitted with shutoff valves or check valves within
30 cm (12 in) of their ends. This will ensure that
only minimal quantities of refrigerant escape to the
atmosphere when the equipment is disconnected
from the A/C system, and that only small amounts
of moisture and other contaminants can enter the
system.
2. Be sure that all equipment including the connecting
hose lines and manifold are compatible with the
refrigerant in the system with which you are going to
work, and that your equipment has been previously
used only with the refrigerant you are about to
recover.
3. Be sure that all shutoff valves are tight before
connecting them to the A/C system.
CAUTION
Z021 - Shutoff valves should be closed at all times
unless they are connected to a vehicle’s A/C system,
a refrigerant storage container, or another piece of
service equipment containing the same refrigerant.
This prevents refrigerant from escaping into the atmo
4. Connect the extraction or recovery equipment to

the A/C system in accordance with the instructions
supplied by the equipment manufacturer.
5. Start the recovery process by turning on the
recovery equipment and extracting the refrigerant
from the A/C system in accordance with the
equipment manufacturer’s instructions.
6. Continue to extract refrigerant until the A/C system
has been brought under a vacuum and there is no
refrigerant remaining in the vehicle system.
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7. Verify that there is no refrigerant remaining in the

system by:
- Shutting off the recovery unit and observing the
system pressure level.
- Waiting five minutes and observing the system
pressure again. If the system pressure has not risen
above atmospheric pressure (0 gauge pressure),
all the refrigerant has been removed and you may
proceed to step 8.
If, after five minutes, the system pressure reading
has risen above atmospheric pressure (0 gauge
pressure), the extraction/recovery process must be
repeated until the pressure reading remains at or
below atmospheric for at least two minutes with the
recovery equipment shut off before proceeding to
step 8.
8. Close the shutoff valves in the service lines.
9. Remove the service lines from the vehicle system.
If the recovery equipment has automatic closing
shutoff valves, verify that they are operating properly
and do not leak.
10. Determine the amount of lubricant removed from
the A/C system during the refrigerant recovery
process. Replenish the A/C system with an equal
volume of new, correct lubricant.
Dispose of the used lubricant in accordance with
applicable federal, state and local requirements.
11. The system is now ready to be serviced or repaired.
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ENVIRONMENT CONTROL Air-conditioning system - Pre delivery

inspection (E.40.C - F.40.A.15)
CS540, CS640, CS520, CS660
1. Keep door and window closed.

2. Use the air-conditioning as much as possible.
3. Use the air-conditioning only with the ventilator in
position I or II.
4. Control the desired temperature with the
air-conditioning knob (thermostat).
5. Regularly pay attention to the following:
The status of the sight glass and the moisture
indicator.
The cleanliness of the condenser and evaporator.
The cleanliness of the air intake filters.
The cleanliness of the air recycling filter.
The water dropping at the drain tubes.
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ENVIRONMENT CONTROL Air-conditioning system - Preliminary

test (E.40.C - F.40.A.20)
CS540, CS640, CS520, CS660
The most important factor in heater air-conditioning troubleshooting is verification of the problem by observing
the system operation and isolating the problem area.
The test ports are located on the high and low pressure hoses where they connect to the compressor. The fittings
conform to SAE J2197 standards.
After the manifold gauge set has been connected and before pressure tests can be made, the system must be
stabilized as follows:
1. Set the parking brake, be sure the multi-function

lever is in neutral, start the engine and close the
cab window and doors.
2. Start the engine and run at fast idle speed
(approximately 1500 RPM).
3. Set the A/C mode switch (3) to "on".
ZEIL04CS0103A0B 1
4. Operate the system at maximum cooling, with the

blower fan at high speed, for 10 minutes to stabilize
all components.
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ENVIRONMENT CONTROL Air-conditioning system - Tool

description (E.40.C - F.40.D.20)
CS540, CS640, CS520, CS660
When using a manifold gauge set to diagnose, recharge or service the air conditioning system.
1. Ensure that all equipment hose lines are fitted with

shutoff valves or check valves within 30 cm (12 in)
of their ends and that the valves are closed. This will
ensure that only minimal quantities of refrigerants
escape to the atmosphere, and that only small
amounts of moisture and other contaminants can
enter the system.
2. Be sure that all equipment including the connecting
hose lines and manifolds are:
- Compatible with the refrigerant in the A/C system.
- Free of all contaminants.
- Used only for the same type of refrigerant in the
system.
3. Be certain that all shutoff valves are shut tight before
connecting them to the A/C system or charging
source.
4. Connect the manifold gauge set to the unit
according to the instructions supplied by the gauge
set manufacturer.
5. Perform the desired diagnostic and service
operation.
6. Close the shutoff valves on the service hoses.
7. Disconnect the hoses from the system.
NOTE: When the manifold gauge set is disconnected
from the air conditioning system and you want to empty it
of refrigerant, or when the center hose is to be moved to
another device which cannot accept refrigerant pressure,
the hoses should be attached to recovery equipment or
recycling equipment to remove the refrigerant, lubricant
and contaminants from the hoses.
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ENVIRONMENT CONTROL Air-conditioning system - Tool usage

(E.40.C - F.40.D.22)
CS540, CS640, CS520, CS660
At times you may question whether or not a container of refrigerant has been recycled. One method is a simple
comparison of the container pressure with theoretical pressure at a known temperature. If the pressure is equal
to or less than a theoretical value established for R-134a of usable purity, the contents of the container does not
contain excess air.
IMPORTANT: Using R-134a with excess air will result in higher system operating pressures and may cause damage
to the A/C system.
1. Store the container for at least 12 hours at a known
temperature of 18.3 ° C (65 ° F), or higher. The
container must not be in direct sunlight or under the
influence of any other direct source of heat.
Carry out all the next steps in the same area in
which the container has been stored, as it is very
important that the temperature of the container is
stable.
2. Attach an appropriate pressure gauge to the
container. This pressure gauge should read in
increments of 6.9 kPa (1 PSI).
3. Use a calibrated thermometer to measure the air
temperature within 100 mm (4 in) of the container
surface.
4. Use this table for R-134a to compare the pressure
in the container with the pressure shown for the
temperature of the tank. If the pressure in the
container is equal to or less than the pressure in
the table, the refrigerant in the container meets the
requirements for excess air.
50_sec50-1_11 1
Temperature vs. Pressure Chart
12145 1 02/07/2004
E.40.C / 39
If the pressure is greater than shown in the table, you may still be able to use it by proceeding to step 5.
5. If the pressure exceeds that of the table, connect
the tank to recovery or recycling equipment in such
a way as to allow you to continue to monitor tank
pressure.
6. Bleed a small amount of vapor from the tank into
the recovery or recycling equipment until the tank
pressure is below that shown in the table for the
temperature at which the tank was stored. Close the
shutoff valves in the recovery/recycling equipment
service hose.
NOTE: This process may cause the temperature of the
tank to drop.
7. Allow the tank temperature to re-stabilize at the
temperature of the storage room by shaking it and
allowing it to sit in the same spot for up to another
12 hours.
8. After making certain that container temperature has
again stabilized to room temperature, repeat step 4.
If the pressure exceeds that in the table for the
storage temperature you measured, the refrigerant
in the tank has too much excess air to be used and
must be recycled or reclaimed.
9. If the refrigerant being checked has been
contaminated with other refrigerant, such as R-12,
the tank pressure may indicate it contains air. If
the tank is vented and the pressures still indicates
a high reading, and there is a possibility of the
R-134a refrigerant being contaminated with R-12,
the container must be sent to a reclaim facility.
12145 1 02/07/2004
E.40.C / 40
ENVIRONMENT CONTROL Air-conditioning system - Check (E.40.C

- F.45.A.10)
CS540, CS640, CS520, CS660
The A/C system should not leak. "Topping off" a leaky air conditioning system perpetuates the escape of refrigerant
to the atmosphere. The proper service procedure is to locate and then correct the leak before putting any refrigerant
into the system.
IMPORTANT: Any refrigerant introduced into the system for the purpose of finding leaks must also be recovered
from the system.
IMPORTANT: Always use the same type of refrigerant for checking leaks as was originally installed.
IMPORTANT: Never use compressed air to detect system leaks. The introduction of air into the system may create
a fire or explosion hazard, may overload the desiccant with moisture, and could contaminate the system with dirt.
1. A small amount of refrigerant leakage is normal.
Much of the normal leakage comes from the slow
seepage of refrigerant through the flexible hoses.
Other common sources of leaks are at joints
between the flexible hose and metal tubing or at
threaded hose connections. These are usually
much larger leaks than the natural seepage through
the walls of the hose and are almost always
repairable. When servicing them it is important that
leakage be minimized.
Be certain to use an electronic leak detector, Tool #
OEM 1486 or equivalent, for detecting R-134a.
12145 1 02/07/2004
E.40.C / 41
ENVIRONMENT CONTROL Air-conditioning system - Check (E.40.C

- F.45.A.10)
CS540, CS640, CS520, CS660
Start the engine and set the throttle at 1500 RPM. Run the engine for ten minutes with the air conditioner set
at maximum cooling and the blower on high speed.
1. Check that the A/C mode button (3) is pushed in,

the temperature control knob is on cold, and the
blower is on the highest speed.
ZEIL04CS0103A0B 1
2. Check that the air-conditioning components are

operating, such as:
Compressor clutch engages when the A/C mode
switch (3) is pushed from "OFF" to "ON" position.
Engine cooling fan is operating.
Blower fan is operating at all speeds.
3. Check the compressor drive belt for slippage.
4. Check the cab air filter to ensure it is clean and free
from obstruction to air flow.
5. Check the evaporator fins. Be sure they are not
plugged or excessively dirty causing insufficient air
flow across the evaporator coil.
6. Check the recirculation filter to ensure that it is clean
and free from obstruction to air flow.
7. Check the condenser core to ensure it is clean and
free from obstruction to air flow.
NOTE: If the compressor clutch fails to engage by
operating the air conditioning mode switch when the
engine is first started, it may indicate an electrical
problem or a malfunction of the electric drive clutch on the
compressor. Review the electrical diagram in this section
for proper diagnosis.
8. If the compressor clutch engages but cuts out
prematurely, the system may be either very low
on refrigerant charge or have a malfunction of the
expansion valve, low-pressure or high pressure
switches. Troubleshoot the system by conducting
the ENVIRONMENT CONTROL Air-conditioning
system - Troubleshooting (E.40.C - G.40.A.10).
12145 1 02/07/2004
E.40.C / 42
ENVIRONMENT CONTROL Air-conditioning system - Charging

(E.40.C - F.60.A.30)
CS540, CS640, CS520, CS660
1. Recharge the system only with the proper virgin

refrigerant or recycled refrigerant purified to meet
SAE purity standard (J2099 for R-134a). Use the
weight method to determine the proper amount of
refrigerant.
12145 1 02/07/2004
E.40.C / 43
ENVIRONMENT CONTROL Air-conditioning system - Filling (E.40.C

- F.60.A.10)
CS540, CS640, CS520, CS660
Refilling the air conditioning system must be done by the weight method. The lubricants used in R-134a tend to
layer onto the walls of the refrigeration system. This layering obscures the view through the sight glass. Visual
methods of refilling R-134a systems will result in improper system charging. For this reason, the old practice of
“topping off" a partially discharged air conditioning system using the sight glass is no longer recommended. The air
conditioning system has a capacity of 3.06 kg (6.75 lb.) of R-134a refrigerant.
1. Contaminants
No mobile air conditioning system can operate for
long without picking up some contaminants in the
refrigerant. The flexible hoses, for example, allow
moisture and air to migrate into the refrigerant
from the outside atmosphere. Moisture and
non-condensable gasses (air) are the most common
contaminants found in mobile air conditioning
systems.
Lubricant and refrigerant that remains in service
equipment can be a contaminant. The lubricant
may have absorbed some moisture and air that has
migrated into the air conditioning system. Some of
the lubricant is captured by and carried along with
the refrigerant. When you recover a refrigerant,
a certain amount of lubricant will be captured
by the extraction or recovery equipment as well.
This lubricant will be drained into a catch bottle or
reservoir for measurement and proper final disposal.
Lubricant that has come out of an air conditioning
system should never be reused. Re-using this oil
may result in contamination of the air conditioning
system with the refrigerant, moisture and air that
has been temporarily absorbed into the oil. Instead,
the A/C system should be refilled with the same
amount of correct fresh oil that was removed in the
service operation. The used oils must be disposed
of in a manner which complies with federal, state
and local disposal requirements.
To avoid contamination between systems using
dissimilar refrigerant, service equipment MUST be
dedicated to a single refrigerant.
12145 1 02/07/2004
E.40.C / 44
Compressor - Remove (E.40.C.31 - F.10.A.10)

CS540, CS640, CS520, CS660
NOTE: Shielding around engine removed for clarity.

1. Recover refrigerant in accordance with the
Refrigerant Recovery Procedure ENVIRONMENT
CONTROL Air-conditioning system - Drain fluid
(E.40.C - F.35.A.20).
NOTE: A 1/2 in ratchet cutout is provided in the arm of
the idler pulley. Because of the orientation of the various
components, this cutout may be unusable.
2. Use a crowbar (1) to release tension from the drive
belt.
Remove the drive belt from the compressor pulley.
10008351 1
3. Detach the compressor clutch electrical connector

(1).
Remove the bolts (2) and (3) to remove the both
supports.
Disconnect the suction line (5) and the discharge
line (4). Cap the line side to prevent moisture or
foreign material from entering the system.
Take off the hose clamp mounting bolt (3).
ZDF0850C 2
4. Remove the compressor mounting bolts and lift the

compressor from the combine.
12145 1 02/07/2004
E.40.C / 45
Compressor - Install (E.40.C.31 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Set the compressor on its mount and secure into

place using the four bolts.
Connect the refrigerant suction line (5) and the
discharge line (4).
Install the both supports and tighten the bolts (2)
and (3).
Attach the clutch electrical connector (1).
ZDF0850C_95 1
2. Use a crowbar (1) to rotate the idler pulley toward

the rear of the combine. Route the drive belt around
the compressor pulley and release pressure on the
crowbar.
10008351_96 2
3. Recharge the refrigerant system in accordance

with the Recharge/Refilling procedure. Refer to
ENVIRONMENT CONTROL Air-conditioning
system - Filling (E.40.C - F.60.A.10).
12145 1 02/07/2004
E.40.C / 46
Compressor Magnetic clutch - Remove (E.40.C.31.80 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Insert the two pins of the front plate spanner into

any two threaded holes of the clutch front plate.
Hold the clutch plate stationary.
Remove the hex nut with a 19 mm socket.
30288 1
2. Remove the clutch plate using a puller. Align the

puller centre bolt to the compressor shaft. Thumb
tighten the 3 puller bolts into the threaded holes.
Turn the centre bolt clockwise until the front plate is
loosened.
30287 2
3. Remove the shaft key by lightly tapping it loose with

a slot screw driver and hammer.
30291 3
12145 1 02/07/2004
E.40.C / 47
4. Remove the internal bearing snap ring.
30290 4
5. Remove the front housing external snap ring.
30292 5
6. Remove the rotor pulley assembly:

Insert the lips of the jaws into the internal bearing
snap ring groove.
30295 6
7. Place the rotor puller shaft protector over the

exposed shaft.
30289 7
12145 1 02/07/2004
E.40.C / 48
8. Align the thumb head bolts to the puller jaws and

finger-tighten.
30286 8
9. Turn the puller centre bolt clockwise until the rotor

pulley is free.
30280 9
10. Remove the field coil.

Loosen the coil lead wire from the clip on top of the
compressor front housing.
30281 10
11. Remove the snap ring and the field coil.
30294 11
12145 1 02/07/2004
E.40.C / 49
Compressor Magnetic clutch - Install (E.40.C.31.80 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the field coil: the coil flange protrusion must

match the hole in the front housing to prevent coil
movement and the lead wire must be correctly
located.
Replace the rotor pulley.
30293 1
2. Support the compressor on the four mounting ears

at the compressor rear side. If using a vise, clamp
only the mounting ears, never the compressor body
itself.
Align the rotor assembly squarely on the front
housing hub.
Using a hammer and a special tool, tap until the
rotor bottoms to the compressor front housing hub.
30283 2
3. Reinstall the internal bearing snap ring.

Reinstall the front housing external snap ring.
30284 3
12145 1 02/07/2004
E.40.C / 50
4. Replace the front plate assembly.

Check that the original clutch shims are in place
on the compressor shaft.
Replace the compressor shaft key.
Align the front plate key way to the compressor
shaft key.
Using a shaft protector, tap the front plate to the
shaft until it has bottomed to the clutch shims.
30282 4
5. Replace the shaft hex nut and torque between 35 -

40 Nm (26 - 29.5 lb ft).
Check the air gap with a feeler gauge (0.4 - 0.8
mm). If the air gap is not consistent around the
circumference, lightly pry up at the minimum
variations. Lightly tap down at points of maximum
variation.
30285 5
12145 1 02/07/2004
E.40.C / 51
Condenser - Remove (E.40.C.32 - F.10.A.10)

CS540, CS640, CS520, CS660

Refrigerant Recovery procedure ENVIRONMENT
(E.40.C - F.35.A.20).
Open the rotary dust screen door with the key (1),
to gain access to the air-conditioning condenser.
ZDA7387A_97 1
2. Disconnect and cap the refrigerant lines (1) from the

condenser. The fittings are different sizes, labeling
should not be required.
IMPORTANT: Use a wrench on the condenser tube nut to
prevent twisting the condenser tube.
10010478 2
3. Remove the two lynch pins (2) to separate the

condenser (3) from the rotary dust screen door (4).
Lift-up the condenser out of his hinges.
ZDF0696B 3
12145 1 02/07/2004
E.40.C / 52
Condenser - Install (E.40.C.32 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Open the rotary dust screen door (1) to gain

access to the mounting area for the air-conditioning
condenser.
ZDA7387A_97 1
2. Hang-up the condenser (3) into the hinges.

Connect the condenser (3) with the rotary dust
screen door (4) and install the two lynch pins (2).
ZDF0696B_98 2
3. Replace the O-rings, and lubricate them with PAG

oil. Attach the hoses (2) to the condenser, and
tighten to the proper torque.
IMPORTANT: Use a wrench on the condenser tube nut to
prevent twisting the condenser tube.
NOTE: The fittings are different sizes.
10010478_99 3
4. Recharge the refrigerant system in accordance with

the Recharge/Refilling Procedure ENVIRONMENT
CONTROL Air-conditioning system - Filling
(E.40.C - F.60.A.10) .
12145 1 02/07/2004
E.40.C / 53
Receiver/drier - Remove (E.40.C.35 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Recover the refrigerant in accordance with the

(E.40.C - F.35.A.20).
Disconnect and cap the refrigerant lines (1) from
the receiver/dryer.
Loosen the hose clamp (2), holding the unit in place.
ZDA6254B 1
2. Remove the unit from the combine.
12145 1 02/07/2004
E.40.C / 54
Receiver/drier - Install (E.40.C.35 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Set the filter-drier in place and secure by tightening

the hose clamp (2).
Inspect the O-rings and replace if necessary.
Lubricate the O-rings with PAG oil, and uncap and
connect refrigerant lines (1).
Tighten the lines to the correct torque
ZDA6254B_101 1

the Recharge/Refilling procedure ENVIRONMENT
(E.40.C - F.60.A.10).
12145 1 02/07/2004
E.40.C / 55
Sensing system Limit switch - Remove (E.40.C.95.85 - F.10.A.10)

CS540, CS640, CS520, CS660

(E.40.C - F.35.A.20).
2. Remove the high pressure switch (2) from the
system.
ZDF0850B 1
12145 1 02/07/2004
E.40.C / 56
Sensing system Limit switch - Install (E.40.C.95.85 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the high pressure switch (2) into the system.
ZDF0850B 1

(E.40.C - F.60.A.10).
12145 1 02/07/2004
E.40.C / 57
Sensing system Limit switch - Remove (E.40.C.95.85 - F.10.A.10)

CS540, CS640, CS520, CS660
Low pressure switch

(E.40.C-F.35.A.20).
2. Remove the low pressure switch (1) from the
system.
ZDF0850B 1
12145 1 02/07/2004
E.40.C / 58
Sensing system Limit switch - Install (E.40.C.95.85 - F.10.A.15)

CS540, CS640, CS520, CS660
Low pressure switch
1. Install the low pressure switch (1) into the system.
ZDF0850B 1

(E.40.C - F.60.A.10).
12145 1 02/07/2004
E.40.C / 59
ENVIRONMENT CONTROL Air-conditioning system -

Troubleshooting (E.40.C - G.40.A.10)
CS540, CS640, CS520, CS660

No cooling A/C mode switch not on. Turn A/C mode switch on.
Temperature control switch not rotated Rotate temperature control
fully counter-clockwise towards the blue counter-clockwise.
index.
Loose or broken compressor drive belt. Check belt and tension. Replace as
required.
Loss of refrigerant. Perform system tests - recharge.
Compressor clutch does not engage. Perform electrical checks of clutch circuit.
Insufficient air flow through evaporator. Check air filter.
Check evaporator core and clean if
required.
Check blower motor operation.
Defective blower fans.
Faulty expansion valve operation. Conduct “System Performance Test" -
replace as needed.
Faulty compressor. Conduct “System Performance Test" -
repair as needed.
Insufficient cooling Dirty evaporator coil and/or filter. Visual inspection - clean.
Temperature control switch not rotated Rotate temperature switch counter-clock-
fully counter- clockwise towards the blue wise.
index.
Dirty condenser core. Visual inspection - clean.
Low refrigerant charge. Perform system tests - recharge.
Water valve partially open. Visual inspection.
Compressor drive belt slipping. Visual inspection - replace or adjust as
needed.
Evaporator icing up. Perform system tests.
Faulty thermostatic switch. Visual inspection of capillary tube to outlet
tube.
Perform system tests - replace if needed.
Faulty expansion valve. Visual inspection of capillary tube to outlet
tube.
Perform system tests - replace if needed.
Faulty blower fan. Visual inspection of fan rotor and fastening
to motor shaft. Repair or replace.
Plugged or restricted filter-drier. Perform system tests - replace if needed.
Moisture in the system. Visually inspect moisture indicator on the
filter-drier.
Perform system tests - evacuate and
recharge.
Replace the filter-drier.
Faulty compressor. Perform system tests - overhaul if needed.
Noisy system Faulty compressor clutch. Replace clutch assembly.
Noise in compressor. Replace compressor.
Excessive charge in system. Perform system test and adjust charge.
12145 1 02/07/2004
E.40.C / 60
ENVIRONMENT CONTROL Air-conditioning system -

Troubleshooting (E.40.C - G.40.A.10)
CS540, CS640, CS520, CS660

Gauge readings: Low refrigerant charge. Perform leak tests and repair.
Low-pressure - Low Evacuate system.
High-pressure - Low Charge system, retest system.
Evaporator air not cold.
Gauge readings: Air or moisture present in system. Replace filter-drier.
Low-pressure - High Evacuate the system.
High-pressure - Normal Charge the system.
Evaporator air not cold. Retest.
Gauge readings: Excessive moisture in system. Discharge system.
Low-pressure - High Replace the filter-drier.
High-pressure - Normal Evacuate system.
Insufficient cooling during Charge the system.
hottest part of day. Retest.
Gauge readings: Filter-drier saturated and releases Discharge system.
Low-pressure - High moisture when outside air temperature is Replace the filter-drier.
High-pressure - Normal high. Evacuate system.
Low-pressure reading Charge the system.
does drop to vacuum Retest.
during test. (normal)
Gauge readings: Defective temperature control Stop engine and shut off A/C.
Low-pressure - Normal (thermostatic) switch. Replace temperature control switch or
High-pressure - Normal evaporator sensor.
Compressor cycles “on" Retest system and check compressor
and “off" too frequently. cycling.
Gauge readings: Overcharged with refrigerant. Check operation of engine cooling fan.
Low-pressure - High Repair as needed.
High-pressure - High Check for overcharge as follows:
Bubbles in sight glass. Recover the system refrigerant R-134a.
Remove condenser assembly, flush and
clean thoroughly.
Replace filter-drier.
Replace any oil lost during recovery.
Charge the system with 3.06 kg (6.75 lb.)
of R-134a refrigerant.
Retest.
Gauge readings: Air and moisture in the system. Discharge the system.
Low-pressure - High Replace filter-drier.
High-pressure - High Evacuate the system.
Evaporator air not cold. Charge the system.
Retest.
Gauge readings: Internal leak in compressor. (reed valves, Recover the system refrigerant R-134a.
Low-pressure - High gasket, worn or scored piston rings or Replace the compressor.
High-pressure - Low cylinder) Evacuate the system.
Evaporator air not cold. Charge the system.
Retest.
Gauge readings: System low on charge. Perform leak test.
Low-pressure - High Recover the system refrigerant R-134a.
High-pressure - Normal Repair leaks.
Insufficient cooling,
Low-pressure reading
does not fluctuate with
manual operation of
the A/C mode switch.
(pressure should drop
until compressor cycles)
12145 1 02/07/2004
E.40.C / 61

Gauge readings: Extremely low refrigerant charge. Perform leak tests and repair.
Low-pressure - Low Evacuate system.
High-pressure - Low Charge system, retest system.
Evaporator air warm.
Gauge readings: Expansion valve not permitting sufficient Check expansion valve as follows:
Low-pressure - Low flow. 1) Set at maximum cooling.
High-pressure - Low Spray CO2 or other gas on valve head or
Evaporator air cool but sensing bulb.
not sufficiently cold. Low-pressure gauge should then show a
vacuum reading.
Retest.
2) If expansion valve is defective as
determined in Step 1, or if the valve inlet
tube shows heavy condensation or frost,
proceed as follows:
Recover the system refrigerant R-134a.
Replace expansion valve.
Evacuate system.
Charge system.
Retest.
Gauge readings: Moisture freezes in expansion valve Discharge system.
Low-pressure - High preventing refrigerant flow. Replace the filter-drier.
High-pressure - Normal Evacuate system.
High pressure reading Charge the system.
drops when low pressure Retest.
reading shows vacuum.
Evaporator air is
sufficiently cold until
low-pressure reading
drops to vacuum, then it
becomes warm.
Gauge readings: Stuck valve. Check expansion valve as follows:
Low-pressure - Low 1) Set at maximum cooling.
High-pressure - Low Spray CO2 or other gas on valve head or
Expansion valve sensing bulb.
inlet tube surface Low-pressure gauge should then show a
shows considerable vacuum reading.
condensation or frost. Retest.
2) If expansion valve is defective as
determined in Step 1, or if the valve inlet
tube shows heavy condensation or frost,
proceed as follows:
Evacuate system.
Charge system.
Retest.
Gauge readings: Improper operation of condenser. Inspect for dirty condenser restricting air
Low-pressure - High flow and cooling.
High-pressure - High
Evaporator air warm.
Liquid line hot.
(condenser outlet to
expansion valve tube)
12145 1 02/07/2004
E.40.C / 62

Gauge readings: Expansion valve allowing too much Check expansion valve.
Low-pressure - High refrigerant to flow through the evaporator. Set for maximum cooling.
High-pressure - High Spray liquid CO2 on expansion valve
Evaporator air warm. head.
Evaporator and hose Low-pressure gauge should show vacuum
to compressor shows reading.
considerable moisture. If the expansion valve is defective, proceed
as follows:
Discharge the system.
Charge the system.
Retest.
If the above test shows expansion valve
operating properly, proceed as follows:
Replace the filter-drier.
Inspect all lines and tubing from the
compressor outlet to the expansion valve.
Replace if needed.
Charge the system.
Retest.
Gauge readings: Restriction in liquid line. Discharge the system.
Low-pressure - low Replace the filter-drier.
High-pressure - high Inspect all lines and tubing from
Insufficient cooling. compressor outlet to expansion valve.
Replace if needed.
Charge the system.
Retest.
12145 1 02/07/2004
E.40.C / 63
Index
Command - Static description (E.40.C.05 - C.30.A.20) 12

CS540, CS640, CS520, CS660
Compressor - General specification (E.40.C.31 - D.40.A.10) 5
CS540, CS640, CS520, CS660
Compressor - Install (E.40.C.31 - F.10.A.15) 46
CS540, CS640, CS520, CS660
Compressor - Remove (E.40.C.31 - F.10.A.10) 45
CS540, CS640, CS520, CS660
Compressor - Static description (E.40.C.31 - C.30.A.20) 13
CS540, CS640, CS520, CS660
Compressor Magnetic clutch - Install (E.40.C.31.80 - F.10.A.15) 50
CS540, CS640, CS520, CS660
Compressor Magnetic clutch - Remove (E.40.C.31.80 - F.10.A.10) 47
CS540, CS640, CS520, CS660
Condenser - Install (E.40.C.32 - F.10.A.15) 53
CS540, CS640, CS520, CS660
Condenser - Remove (E.40.C.32 - F.10.A.10) 52
CS540, CS640, CS520, CS660
Condenser - Static description (E.40.C.32 - C.30.A.20) 14
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - A/C schema (E.40.C - C.20.B.35) 8
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Charging (E.40.C - F.60.A.30) 43
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Cleaning (E.40.C - F.30.A.10) 32
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Component localisation (E.40.C - C.40.B.20) 11
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Drain fluid (E.40.C - F.35.A.20) 34
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Dynamic description (E.40.C - C.30.A.10) 10
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Filling (E.40.C - F.60.A.10) 44
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Functional diagram (E.40.C - C.20.A.70) 7
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - General specification (E.40.C - D.40.A.10) 5
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - General specification (E.40.C - D.40.A.10) 5
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Pre delivery inspection (E.40.C - F.40.A.15) 36
CS540, CS640, CS520, CS660
12145 1 02/07/2004
E.40.C / 64
ENVIRONMENT CONTROL Air-conditioning system - Preliminary test (E.40.C - F.40.A.20) 37
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Service instruction (E.40.C - F.10.A.05) 28
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Special tools (E.40.C - D.20.A.40) 5
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Static description (E.40.C - C.30.A.20) 9
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Storing (E.40.C - F.35.A.02) 33
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Tool description (E.40.C - F.40.D.20) 38
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Tool usage (E.40.C - F.40.D.22) 39
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Troubleshooting (E.40.C - G.40.A.10) 60
CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Air-conditioning system - Troubleshooting (E.40.C - G.40.A.10) 61
CS540, CS640, CS520, CS660
Receiver/drier - Install (E.40.C.35 - F.10.A.15) 55
CS540, CS640, CS520, CS660
Receiver/drier - Remove (E.40.C.35 - F.10.A.10) 54
CS540, CS640, CS520, CS660
Receiver/drier - Static description (E.40.C.35 - C.30.A.20) 15
CS540, CS640, CS520, CS660
Sensing system - Dynamic description (E.40.C.95 - C.30.A.10) 16
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Sensing system Limit switch - Static description (E.40.C.95.85 - C.30.A.20) 27
CS540, CS640, CS520, CS660
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ENVIRONMENT CONTROL Heating, ventilation and air-conditioning

- 40.D
CS540
CS640
CS520
CS660
12146 1 02/07/2004
E.40.D / 1
Contents
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - 40.D
DIAGNOSTIC
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Problem solving 3

(E.40.D - G.40.A.30)
CS540, CS640, CS520, CS660
Ventilation system
Ventilation system - Testing (E.40.D.60 - G.40.A.20) 4
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Electrical control
Electrical control - Testing (E.40.D.90 - G.40.A.20) 8
CS540, CS640, CS520, CS660
12146 1 02/07/2004
E.40.D / 2
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning

- Problem solving (E.40.D - G.40.A.30)
CS540, CS640, CS520, CS660
OPERATION
BLOWER CONTROL CIRCUIT

The climate control is a manually controlled system for providing heat and air conditioning that consists of the
following functions:
Operator control of the blower fan (3 speeds)
Operator selection of A/C "ON" and A/C "OFF".
Electronic control of heater valve and compressor clutch.
The fan speed of the blower motor is controlled by a four position switch ("Off", "Low", "Med", and "High") The blower
speed is controlled by a power resistor that determines various voltage drops to provide the different blower speeds.
The "OFF" position will also turn off the A/C if it is on.
HEATING/AIR CONDITIONING CONTROL CIRCUIT
Control is achieved through the use of a dash mounted potentiometer which operates over a range from maximum
A/C to maximum heat. A/C is achieved by activating the A/C compressor and heat is achieved by opening an
electronically operated water valve.
Additionally, the A/C can be turned ON or OFF via the A/C switch but there is no visual indication of operation.
DEHUMIDIFY CONTROL CIRCUIT
Dehumidification (A/C and heat on at the same time) can be achieved by placing the two position toggle switch
in the A/C ON position.
A/C COMPRESSOR PROTECTION CIRCUIT
The compressor is protected through the use of high and low refrigerant pressure switches. These switches will not
allow compressor operation if the refrigerant pressure is above or below a preset threshold. If the compressor is
turned OFF for any reason, it can be reset by either turning the fan switch or the toggle switch OFF and then ON.
TROUBLESHOOTING
Before troubleshooting the Manual Climate control system, make sure that the following operating conditions are met:
C. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals
D. Refrigerant fill must be correct.
E. Condenser fins are clean and unrestricted.
F. Engine cooling fan must be operating correctly (fan clutch).
G. Compressor drive belt properly tensioned and in good condition.
12146 1 02/07/2004
E.40.D / 3
CAUTION
CAUTION

Climate control module is Fuse #6 A - Climate control module power and
inoperative Circuit(s) ground supply test Electrical control -
Cab roof printed circuit Testing (E.40.D.90 - G.40.A.20)
Climate control module If test A is okay, install a new climate
control module.
Blower fan inoperative Climate Control Module A - Climate Control Module power and
(All speed positions) ground supply test Electrical control -
Testing (E.40.D.90 - G.40.A.20)
Fuses #15 and #35 B - Blower fan circuit test Ventilation
Circuit(s) system - Testing (E.40.D.60 - G.40.A.20)
Cab roof printed circuit
Blower fan
Climate Control Module
Blower fan inoperative Circuit(s) C - Blower fan (low speed) circuit test
(low speed) Fan speed (low) relay Ventilation system - Testing (E.40.D.60 -
Cab roof printed circuit G.40.A.20)
Blower fan
Blower Fan inoperative Circuit(s) D - Blower fan (medium speed) circuit test
(medium speed) Fan speed (medium) relay Ventilation system - Testing (E.40.D.60 -
Blower fan inoperative circuit(s) E - Blower fan (high speed) circuit test
(high speed) Fan speed (high) relay Ventilation system - Testing (E.40.D.60 -
Blower fan
Ventilation system - Testing (E.40.D.60 - G.40.A.20)

CS540, CS640, CS520, CS660
12146 1 02/07/2004
E.40.D / 4
CAUTION
WARNING

1 Remove the fan speed (low) relay 12 volts. Blown fuse #35.
K38. If good reading, go to test point 3. Open circuit in cab roof printed
Turn the key start "ON". circuit.
Check for 12 volts at relay Go to next test point.
2 Disconnect cab roof printed circuit 12 volts. Blown fuse #15.
connector X135. If good reading, install a new cab Open circuit between cab roof
Check for 12 volts at connector roof printed circuit. printed circuit connector X135 and
X135, circuit 413 (RD). fuse printed circuit X191, circuit 413
(RD).
Open circuit in fuse printed circuit.
3 Disconnect blower fan connector Less than 1 ohm resistance. Open circuit between blower fan
X81. If good reading, continue with next connector X81 (pin 3 and 4) and
Check for a ground at connector step. ground, circuit 283 (ZW).
X81 (pin 3 and 4).
4 Reconnect blower fan connector 12 volts. Climate Control Module.
X81. If good reading, install a new blower
Turn the key start "ON". fan.
Select blower switch (low) position.
Check for 12 volts at relay

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Remove the fan speed (low) relay 12 volts. Open circuit in cab roof printed
K38. If good reading, continue with next circuit.
Turn the key start "ON". step.
12146 1 02/07/2004
E.40.D / 5

K38 (pin 2). step.
3 Turn the key start "ON". 12 volts. Open in circuit 293 (WT).
Select blower switch (low) position. If good reading, go to test point 5. Climate Control Module.
4 Disconnect Climate Control Module Less than 1 ohm. Open circuit between fan speed
connector X82. If good reading, install a new (low) relay connector K38 (pin
Measure resistance between Climate Control Module. 1) and Climate Control Module
connector K38 (pin 1) and connector connector X82 (pin 5), circuit 293
X82 (pin 5). (WT).
5 Turn the key start "OFF". 12 volts. Fan speed (low) relay K38.
Install the fan speed (low) relay K38. If good reading, install a new blower Open circuit between fan speed
Disconnect blower fan connector fan. (low) relay connector K38 (pin 3)
X81. and blower fan connector X81 (pin
Turn the key start "ON". 8), circuit 290 (WT).
Measure the voltage at connector Go to next test point.
X81 (pin 8).
6 Turn the key start "OFF". Less than 1 ohm. Open circuit between fan speed
Remove the fan speed (low) relay If good reading, install a new fan (low) relay connector K38 (pin 3)
K38. speed (low) relay K38. and blower fan connector X81 (pin
Measure resistance between 8), circuit 290 (WT).
connector K38 (pin 3) and blower
fan connector X81 (pin 8).

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Remove the fan speed (medium) 12 volts. Open circuit in cab roof printed
Relay K39. If good reading, continue with next circuit.
K39 (pin 2). step.
Select blower switch (medium) If good reading, go to test point 5. Climate Control Module.
position. Go to next test point.
12146 1 02/07/2004
E.40.D / 6

4 Disconnect Climate Control Module Less than 1 ohm. Open circuit between fan speed
connector X82. If good reading, install a new (medium) relay connector K39 (pin
Measure resistance between Climate Control Module. 1) and Climate Control Module
X82 (pin 6). (WT).
5 Turn the key start "OFF". 12 volts. Fan speed (medium) relay K39.
Install the fan speed (medium) relay If good reading, install a new blower Open circuit between fan speed
K39. fan. (medium) Relay connector K39 (pin
Disconnect blower fan connector 3) and Blower Fan connector X81
X81. (pin 6), circuit 291 (WT).
Turn the key start "ON". Go to next test point.
Measure the voltage at connector
X81 (pin 6).
Remove the fan speed (medium) If good reading, install a new fan (medium) relay connector K39 (pin
relay K39. speed (medium) relay K39. 3) and blower fan connector X81
Measure resistance between (pin 6), circuit 291 (WT).
fan connector X81 (pin 6).

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Remove the fan speed (high) relay 12 volts. Open circuit in cab roof printed
K40. If good reading, continue with next circuit.
K40 (pin 2). step.
Select blower switch (high) position. If good reading, go to test point 5. Climate Control Module.
4 Disconnect climate control module Less than 1 ohm. Open circuit between fan speed
connector X82. If good reading, install a new climate (high) relay connector K40 (pin
Measure resistance between control module. 1) and climate control module
X82 (pin 7). (WT).
12146 1 02/07/2004
E.40.D / 7

5 Turn the key start "OFF". 12 volts. Fan speed (high) relay K40.
Install the fan speed (high) relay If good reading, install a new blower Open circuit between fan speed
K40. fan. (high) relay connector K40 (pin 3)
Disconnect blower fan connector and blower fan connector X81 (pin
X81. 12 and 14), circuit 292 (WT).
Turn the key start "ON". Go to next test point.
Measure the voltage at connector
X81 (pin 12 and 14).
Remove the fan speed (high) relay If good reading, install a new fan (high) relay connector K40 (pin 3)
K40. speed (high) relay K40. and blower fan connector X81 (pin
Measure resistance between 12 and 14), circuit 292 (WT).
fan connector X81 (pin 12 and 14).
Electrical control - Testing (E.40.D.90 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect Climate Control Module 12 volts. Blown fuse #6.
connector X82. If good reading, continue with next Open circuit between Climate
Turn the key start "ON" . step. Control Module connector X82 (pin
Check for 12 volts at connector X82 3) and fuse #6, circuit 110 (OR).
(pin 3).
Check for a ground at Climate If good reading, Climate Control circuit.
Control Module connector X82 (pin Module wiring is okay. Open circuit between Climate
13). Control Module connector X82 (pin
13) and ground, circuit 283 (ZW).
12146 1 02/07/2004
E.40.D / 8
Index
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - 40.D
Electrical control - Testing (E.40.D.90 - G.40.A.20) 8

CS540, CS640, CS520, CS660
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Problem solving (E.40.D - 3
G.40.A.30)
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
12146 1 02/07/2004
E.40.D / 9
12146 1 02/07/2004
E.40.D / 10
SAFETY SECURITY ACCESSORIES Safety - 50.B
CS540
CS640
CS520
CS660
12147 1 02/07/2004
E.50.B / 1
Contents
DIAGNOSTIC
Back up alarm
Back up alarm - Short circuit to ground (E.50.B.82 - G.30.B.53) 3
CS540, CS640, CS520, CS660
Audible alert
Audible alert Horn - Testing (E.50.B.84.50 - G.40.A.20) 10
CS540, CS640, CS520, CS660
12147 1 02/07/2004
E.50.B / 2
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
Back up alarm - Short circuit to ground (E.50.B.82 - G.30.B.53)

CS540, CS640, CS520, CS660
E630 - REVERSE DRIVE SIGNAL LINE SHORTED TO GROUND

operation.
Context:
A short to ground on circuit 021 (WT) would blow the fuse F3 when the reverse drive buzzer switch is closed
(reverse drive selected).
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the reverse drive buzzer switch connector, CCM connector X141, in-line harness connectors X10,
X161 and the reverse drive buzzer connector X11.

A. Disconnect connector X141, X161 and X11. Check between connector:

X141 pin 33, circuit (021) (WT) and ground

A. Turn the keystart OFF. Ensure reverse drive is not selected. Check between connector X161 pin K,
circuit (021) (WT) component side and ground. If a short to ground is indicated, repair or replace the
B. If a short to ground is not indicated, install a new reverse drive buzzer. If the fault is still present,
download the correct level of software. If the fault re-occurs, remove and replace the CCM.

(A.30.A - C.20.E.05)
CS540 1260 > 1260
CS640 1260 > 1260

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E.50.B / 3

Line: 1030 - 1360
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E.50.B / 4
55_a3cs007 1
12147 1 02/07/2004
E.50.B / 5

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1030 - 1360
12147 1 02/07/2004
E.50.B / 6
vfil04cs0008h0a 2
12147 1 02/07/2004
E.50.B / 7

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 1030 - 1360
12147 1 02/07/2004
E.50.B / 8
vfil04cs0009h0a 3
12147 1 02/07/2004
E.50.B / 9
Audible alert Horn - Testing (E.50.B.84.50 - G.40.A.20)

CS540, CS640, CS520, CS660
CAUTION
WARNING

1 Disconnect the road lights switch 12 volts. Open circuit between road light
connector X148. If good reading, continue with next switch connector X148 (pin 8),
Check for 12 volts at connector step. circuit 199 (RD) and In-line harness
X148 (pin 8), (RD). connector X7 (pin P).
2 Measure the resistance between Less than 1 ohm, when the horn Road lights switch.
the connector X148 (pin 8 and 9) switch is closed.
component side. Open circuit, when the horn switch
is open.
If good reading, continue with next
step.
3 Disconnect the horn connector (pin Less than 1 ohm. Open circuit between horn connector
1) (ZW). If good reading, continue with next (pin 1), circuit 128 (ZW) and ground.
Check for a ground at the horn step.
connector (pin 1), (ZW).
4 Disconnect the horn connector (pin Less than 1 ohm. Open circuit between horn connector
1) (WT). If good reading, Install a new horn. (pin 1), circuit 196 (WT) and road
Measure the resistance between light switch connector X148 (pin 9),
the horn connector (pin 1) (WT) and circuit 196 (WT).
connector X148 (pin 9), (WT).
12147 1 02/07/2004
E.50.B / 10
Index
Audible alert Horn - Testing (E.50.B.84.50 - G.40.A.20) 10

CS540, CS640, CS520, CS660
Back up alarm - Short circuit to ground (E.50.B.82 - G.30.B.53) 3
CS540, CS640, CS520, CS660
12147 1 02/07/2004
E.50.B / 11
PRINTED IN BELGIUM
12141 1 02/07/2004
REPAIR MANUAL
TOOL POSITIONING
CS540
CS640
CS520
CS660
12148 1 02/07/2004
G
Contents
TOOL POSITIONING - G
LIFTING G.10.A
CS540, CS640, CS520, CS660
LEVELLING G.30.A
CS540, CS640, CS520, CS660
12148 1 02/07/2004
G
LIFTING - 10.A
CS540
CS640
CS520
CS660
12149 1 02/07/2004
G.10.A / 1
Contents
LIFTING - 10.A
FUNCTIONAL DATA
Control valve
Control valve - Static description (G.10.A.13 - C.30.A.20) 4
CS540, CS640, CS520, CS660
Control valve - Dynamic description (G.10.A.13 - C.30.A.10) 6
CS540, CS640, CS520, CS660
Cylinder
Cylinder - Sectional view (G.10.A.26 - C.10.A.30) 9
CS540, CS640, CS520, CS660
SERVICE
Command valve
Command valve Header lift valve - Remove (G.10.A.12.20 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Command valve Header lift valve - Install (G.10.A.12.20 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Cylinder
Cylinder - Service instruction (G.10.A.26 - F.10.A.05) 12
CS540, CS640, CS520, CS660
DIAGNOSTIC
Command
Command Header position switch - Short circuit to ground (G.10.A.05.80 - G.30.B.53) 13
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Command Header resume switch - Short circuit to ground (G.10.A.05.83 - G.30.B.53) 31
CS540, CS640, CS520, CS660
Command valve
Command valve Header lift valve - Open circuit (G.10.A.12.20 - G.30.B.50) 40
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Control valve
Control valve - Open circuit (G.10.A.13 - G.30.B.50) 58
CS540, CS640, CS520, CS660
Electronic control
Electronic control - Short circuit to ground (G.10.A.92 - G.30.B.53) 67
CS540, CS640, CS520, CS660
12149 1 02/07/2004
G.10.A / 2
Sensing system
Sensing system Height sensor - Short circuit to ground (G.10.A.95.80 - G.30.B.53) 76
CS540, CS640, CS520, CS660
Sensing system Height sensor - Short circuit to B+ (G.10.A.95.80 - G.30.B.54) 81
CS540, CS640, CS520, CS660
Sensing system Pressure sensor - Short circuit to ground (G.10.A.95.81 - G.30.B.53) 86
CS540, CS640, CS520, CS660
Sensing system Pressure sensor - Short circuit to B+ (G.10.A.95.81 - G.30.B.54) 95
CS540, CS640, CS520, CS660
12149 1 02/07/2004
G.10.A / 3
TOOL POSITIONING - LIFTING
Control valve - Static description (G.10.A.13 - C.30.A.20)

CS540, CS640, CS520, CS660
Operation of the control valve

To avoid pressure shocks in the hydraulic circuit, an accumulator (11) is installed to absorb the pressure peaks.
Accumulator (11) is installed on the pressure side of the header cylinders (9), separated by a control valve (10)
which has two positions.
ZDF0418A 1
• Position 1: Full oil flow through the valve. (the valve is activated electrically)
• Position 0: Restricted oil flow through the valve. (the valve is electrically not activated)
As the electric circuits pilots the header height control valve (8) in four different operation modes, control valve (10)
will also be influenced. For the impact of the different modes on the header height system, refer to the CS Operators
manual, "SECTION 3 - FIELD AND SITE OPERATION"; paragraph headed: “Operation modes".
1. Transport mode:
• Control valve (10) in position 1

Conditions:
During lifting, lowering or in neutral position of the header.
2. Compensation mode:

Condition:
During automatic operation.

Condition:
During manual lifting or lowering of the header until two seconds after releasing the header up/down
switches.
3. Stubble height or Autofloat mode:

Condition 1:
From start of activation of automatic operation until three seconds after reaching the preset stubble height.
Condition 2:
During manual lifting or lowering of the header until two seconds after releasing the header up/down
switches.
12149 1 02/07/2004
G.10.A / 4
NOTE: The control valve (10), accumulator (11) and pressure sensor (12) are installed at the right-hand side
behind the traction axle.
ZDA7561A_57 2
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G.10.A / 5
Control valve - Dynamic description (G.10.A.13 - C.30.A.10)

CS540, CS640, CS520, CS660
NEUTRAL POSITION
Most of the oil will flow to the main valves and a small amount of oil will enter the return system. This will avoid
overheating of the oil in the neutral position of the control spool (8b).
° The header height control spool (8b) remains in neutral position (no electric activation of the solenoids).
° Before starting the engine (no pump pressure) load sensing valve (8a) will be pushed against the plug on the
left-hand side due to the spring tension on the other side.
After starting the engine (pump pressure will be built up), pump pressure is also available at (7c) of the load sensing
valve. This pressure opens the load sensing valve against the spring tension and the return pressure.
Now most of the pump oil capacity flows towards the main hydraulic control valves.
° A limited amount of oil flows towards control spool (8b) into the return system.
° A lift check valve (8g) prevents the oil in the header cylinders from returning towards the control valve (8b).
° Load shocks on the header cylinders are absorbed by a pressure relief valve (8h) set at 200 bar.
ZEIL04CS0106H0B 1
12149 1 02/07/2004
G.10.A / 6
HEADER LIFT POSITION

During lifting of the header, most of the oil flows towards the header cylinders. A small amount of oil (4 L/min) will
always flow to the main hydraulic valves.
° Control spool (8b) will be moved to the left due to the movement of the electric solenoid.
Now pump oil flow passes the control spool (8b) and flows into pilot line (8d).
This pushes the load sensing valve (8a) to the left, assisted by the spring tension. The complete pump capacity (4
L/min) will flow towards the lift check valve. Trapped oil behind the lift check valve (8g) will be drained through line
(8j). Now valve (8g) will be moved to the left allowing oil flow towards the header cylinders.
ZEIL04CS0107H0B 2
12149 1 02/07/2004
G.10.A / 7
HEADER LOWERING POSITION

During lowering of the header, the header cylinders will be connected to the return system by exerting indirect
pressure on the lift check valve.
° Control spool (8b) will be moved to the right due to the movement of the electric solenoid. Pump oil flow is able to
pass the control valve towards the right-hand side of the flow limiter (8f). Flow limiter (8f) will be pushed to the left
against the spring tension and header weight. Due to that movement, lift check valve (8g) will also pushed open
allowing oil flow from the header towards the return system.
° The cylinder return oil flow is restricted by control spool (8b). This creates a pressure between control spool
(8b) and the header cylinders. This pressure is seated on the left-hand side of flow limiter (8f) and acts against
the pressurized oil on the right-hand side.
° A heavier header installation will increase the return pressure located on the left-hand side of flow limiter (8f) which
will be pushed more to the right (pump pressure remains the same). This will affects the position of the lift check
valve (8g) resulting in a reduced header lowering speed, i.e. the basic lowering speed.
° Oil flow restrictor (8i) affects the header lowering speed as follows:
Permitting more oil flow towards the return system than towards the flow limiter (8f) will decrease the pressure on
the right-hand side of the flow limiter (8f).
This will result in a lower header lowering speed.
Less oil flow will increase the header lowering speed.
° Oil flow restrictor (8i) is factory-adjusted and has only one correct position which must not be changed.
Repositioning of the restrictor will result in subsequent damage of the different valve components.
ZEIL04CS0108H0B 3
12149 1 02/07/2004
G.10.A / 8
Cylinder - Sectional view (G.10.A.26 - C.10.A.30)

CS540, CS640, CS520, CS660
CAUTION
ZDF0429A 1
Header lift cylinder
1 Cylinder housing 2 Piston rod

3 Seal 4 Seal
5 Scraper ring 6 Locking wire
7 Seal 8 Seal
12149 1 02/07/2004
G.10.A / 9
Command valve Header lift valve - Remove (G.10.A.12.20 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Start the engine.

valves.
3. Stop the engine.
CAUTION
stopped rotating
IMPORTANT: Be sure that the area around the valve

is clean before removing them. Dirt contamination will
cause hydraulic component damage and/or failure. Use
caution while washing to keep electrical components as
dry as possible.
4. Drain the hydraulic oil from the reservoir trough
the hose and catch the oil into a clean suitable
container. (Refer to the CS Operator’s Manual:
"Section 4 - Lubrication and Maintenance")
5. On the engine compartment, remove the support
with the step by removing the bolts (1).
ZEIL04CS0031A0B 1
6. Disconnect the electrical connectors from the valve

solenoids.
7. Loosen and disconnect the hydraulic line fittings (2)
from the valve. Cap and plug all lines and fittings.
ZEIL04CS0029A0B 2
12149 1 02/07/2004
G.10.A / 10
Command valve Header lift valve - Install (G.10.A.12.20 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the valve onto his place and connect the

hydraulic line fittings (2) onto the valve.
ZEIL04CS0029A0B 1
2. Connect the electrical wires to the valve solenoids.

3. Install the support with the step and tighten with the
bolts (1).
ZEIL04CS0031A0B 2

5. Fill the hydraulic reservoir with proper type and
amount of hydraulic fluid. (Refer to the CS
operator’s manual: "Lubrication and Maintenance")
6. Start the engine and check all connections for leaks.
7. Check the hydraulic oil level.
12149 1 02/07/2004
G.10.A / 11
Cylinder - Service instruction (G.10.A.26 - F.10.A.05)

CS540, CS640, CS520, CS660
CAUTION
Make sure to order the correct seal kit:
"Header lift cylinder with a locking wire on the piston"
Proceed as follows:
1. Move the piston until the locking wire (1) is visible

through the hydraulic pipe connection.
Turn the piston while gently pushing the locking wire
(1) into the groove (2) with a screwdriver.
Remove the piston.
ZDF0550A 1
2. To install, slide the piston in the cylinder.

Reinstall the locking wire (1) in its original groove
(3).
ZDF0551A 2
12149 1 02/07/2004
G.10.A / 12
Command Header position switch - Short circuit to ground

(G.10.A.05.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E231 - HEADER UP (SLOW) SWITCH (S29) SHORT TO GROUND OR +VE

operation.
Context:
A short to ground on circuit (153) would blow the fuse F3 when the header up (slow) switch is used.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty switch
Solution:
1. Check the multifunction handle connector X123, fuse printed circuit connector X122, CCM connector X141,
and the in-line harness connector X160.

A. Disconnect the CCM connector X141. Turn the keystart ON. Measure the voltage between connector
X141 pin 2, circuit (153) (WT) and ground. If a voltage is indicated, continue to step 3.

A. Turn the keystart OFF. Disconnect the multifunction handle connector X123. Turn the keystart ON.
Measure the voltage between connector X141 pin 2, circuit (153) (WT) and ground. If a voltage is
indicated, repair or replace the harness as required.
B. If the harness is okay, remove and replace the header control switch.
A. Turn the keystart OFF. Check between connector X141 pin 2, circuit (153) (WT) and ground. If a short
to ground is indicated, repair or replace the harness as required.
the CCM.
12149 1 02/07/2004
G.10.A / 13

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 14
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 15

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 16
vfil04cs0010h0a 2
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G.10.A / 17

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
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G.10.A / 18
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 19

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 20
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 21
Command Header position switch - Short circuit to ground

(G.10.A.05.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E233 - HEADER UP/DOWN (FAST) SWITCHES (S50/S51) SHORT TO GROUND OR +VE

operation.
Context:
A short to ground on circuit (191) would blow the fuse F3 when the header up/down (fast) switch is used.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty switch
Solution:


A. Check between connector X141 pin 40, circuit (191) (WT) and ground. If a short to ground is indicated,
repair or replace the harness as required.
the CCM.
12149 1 02/07/2004
G.10.A / 22

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 23
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 24

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 25
vfil04cs0010h0a 2
12149 1 02/07/2004
G.10.A / 26

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 27
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 28

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 29
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 30
Command Header resume switch - Short circuit to ground

(G.10.A.05.83 - G.30.B.53)
CS540, CS640, CS520, CS660
E240 - AUTOMATIC HEADER HEIGHT CONTROL SWITCH (S47) SHORT TO GROUND

operation.
Context:
A short to ground on circuit (167) would blow the fuse F3 when the automatic header height control switch is used.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty switch
Solution:

A. Disconnect connector X141. Check between connector X141 pin 16, circuit (167) (WT) and ground. If a
the CCM.

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

12149 1 02/07/2004
G.10.A / 31

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 32
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 33

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 34
vfil04cs0010h0a 2
12149 1 02/07/2004
G.10.A / 35

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 36
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 37

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 38
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 39
Command valve Header lift valve - Open circuit (G.10.A.12.20 -

G.30.B.50)
CS540, CS640, CS520, CS660
E270 - HEADER UP (Y18) PWM OUTPUT OPEN OR SHORT CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
4. Faulty header height up solenoid
Solution:
1. Check the fuse printed circuit connector X122, header height up solenoid connector Y18, CCM connector
X141, in-line harness connectors X12 and X160, and the header up relay K18.


A. Turn the keystart OFF. Disconnect the header up relay K18. Turn the keystart ON. Measure the
voltage between connector X141 pin 15, circuit (155) (WT) and ground. If a voltage is indicated, repair
B. If the harness is okay, remove and replace the header up relay K18.
A. Turn the keystart OFF. Disconnect the header height up solenoid connector Y18. Check between
connector X141 pin 15, circuit (155) (WT) and ground. If a short to ground is indicated, repair or replace
the harness as required.

A. Check between connector X141 pin 15, circuit (155) (WT) and connector Y18 pin 2, circuit (155) (WT). If
an open circuit is indicated, repair or replace the harness as required.

A. Check between connector Y18 pin 1, circuit (157) (BL) and ground. If an open circuit is indicated, repair
12149 1 02/07/2004
G.10.A / 40
B. If the harness is okay, remove and replace the header height up solenoid. If the fault is still present,

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 41
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 42

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 43
vfil04cs0010h0a 2
12149 1 02/07/2004
G.10.A / 44

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 45
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 46

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 47
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 48
Command valve Header lift valve - Open circuit (G.10.A.12.20 -

G.30.B.50)
CS540, CS640, CS520, CS660
E271 - HEADER DOWN (Y19) PWM OUTPUT OPEN OR SHORT CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
4. Faulty header height down solenoid
Solution:
1. Check the fuse printed circuit connector X122, header height down solenoid connector Y19, CCM connector
X141, in-line harness connectors X12, and X160, and the header down relay K19.

X141 pin 5, circuit (156) (GR) and ground. If a voltage is indicated, continue to step 3.

A. Turn the keystart OFF. Disconnect the header up relay K19. Turn the keystart ON. Measure the
voltage between connector X141 pin 5, circuit (156) (GR) and ground. If a voltage is indicated, repair
B. If the harness is okay, remove and replace the header down relay K19.
A. Turn the keystart OFF. Disconnect the header height down solenoid connector Y19. Check between
connector X141 pin 5, circuit (156) (GR) and ground. If a short to ground is indicated, repair or replace

A. Check between connector X141 pin 5, circuit (156) (GR) and connector Y19 pin 2, circuit (156) (GR). If

12149 1 02/07/2004
G.10.A / 49
B. If the harness is okay, remove and replace the header height down solenoid. If the fault is still present,

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 50
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 51

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 52
vfil04cs0010h0a 2
12149 1 02/07/2004
G.10.A / 53

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 54
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 55

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 56
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 57
Control valve - Open circuit (G.10.A.13 - G.30.B.50)

CS540, CS640, CS520, CS660
E280 - HEADER HEIGHT CONTROL COMPENSATION (Y20) PWM OUTPUT OPEN OR SHORT CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty header height control compensation solenoid
Solution:
1. Check the header height control compensation solenoid connector Y20, CCM connector X141, and the
in-line harness connector X26.

X141 pin 7, circuit (163) (WT) and ground. If a voltage is indicated, repair or replace the harness as
required.

A. Turn the keystart OFF. Disconnect the header height control compensation solenoid connector Y20.
Check between connector X141 pin 7, circuit (163) (WT) and ground. If a short to ground is indicated,
repair or replace the harness as required.


A. Check between connector Y20 pin 1, circuit (112) (ZW) and ground. If an open circuit is indicated, repair
B. If the harness is okay, remove and replace the header down solenoid. If the fault is still present,
12149 1 02/07/2004
G.10.A / 58

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 59
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 60

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 61
vfil04cs0010h0a 2
12149 1 02/07/2004
G.10.A / 62

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 63
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 64

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 65
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 66
Electronic control - Short circuit to ground (G.10.A.92 - G.30.B.53)

CS540, CS640, CS520, CS660
E232 - HEADER DOWN (SLOW) SWITCH (S30) SHORT TO GROUND OR +VE

operation.
Context:
A short to ground on circuit (154) would blow the fuse F3 when the header down (slow) switch is used.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty switch
Solution:


Measure the voltage between connector X141 pin 30, circuit (154) (GR) and ground. If a voltage is
A. Turn the keystart OFF. Check between connector X141 pin 30, circuit (154) (GR) and ground. If a short
the CCM.

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260
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G.10.A / 67

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 68
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 69

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 70
vfil04cs0010h0a 2
12149 1 02/07/2004
G.10.A / 71

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 72
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 73

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 74
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 75
Sensing system Height sensor - Short circuit to ground

(G.10.A.95.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E201 - HEADER HEIGHT SENSOR (R2) SHORT TO GROUND OR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty header height sensor
Solution:
1. Check the header height sensor connector X39 and the in-line harness connectors X19, X40, X111, X112
and X163.

A. Disconnect connector X39. Check between connector X39 pin 1, circuit (160) (BL) and ground. If an

A. Turn the keystart ON. Measure the voltage between connector X39 pin 3, circuit (161) (PK) and ground.
If the voltage indicated is less than +4 Volts, repair or replace the harness as required.
B. If the voltage indicated is approximately +5 Volts, continue to step 4.

A. Turn the keystart OFF. Disconnect the CCM connector X142. Check between connector X39 pin 2,
circuit (165) (GE) and ground. If a short to ground is indicated, repair or replace the harness as required.

A. Check between connector X39 pin 2, circuit (165) (GE) and X142 pin 36 circuit (165) (GE). If an open
circuit is indicated, repair or replace the harness as required.
B. If the harness is okay, remove and replace the header height sensor. If the fault is still present, download
the correct level of software. If the fault re-occurs, remove and replace the CCM.
12149 1 02/07/2004
G.10.A / 76

(A.30.A - C.20.E.07)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 1880
Line: 1880 - 2040
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G.10.A / 77
06_53_56_01 1
12149 1 02/07/2004
G.10.A / 78

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

X19. Header 1880
Line: 1880 - 2040
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G.10.A / 79
vfil04cs0013h0a 2
12149 1 02/07/2004
G.10.A / 80
Sensing system Height sensor - Short circuit to B+ (G.10.A.95.80 -

G.30.B.54)
CS540, CS640, CS520, CS660
E202 - HEADER HEIGHT SENSOR (R2) SHORT CIRCUIT TO +VE
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty header height sensor
Solution:
1. Check the header height sensor connector X39 and the in-line harness connectors X19, X40, X111, and X163.

2. Check for +8 Volts or +12 Volts.
A. Disconnect connector X39. Turn the keystart ON. Measure the voltage between connector X39 pin 3,
circuit (161) (PK) and ground. If the voltage indicated is greater than +5 Volts, repair or replace the
harness as required. If the fault is still present. Download the correct level of software. If the fault

A. Turn the keystart OFF. Disconnect the CCM connector X142. Turn the keystart ON. Measure the
voltage between connector X39 pin 2, circuit (165) (GE) and ground. If a voltage is indicated, repair

(A.30.A - C.20.E.07)
CS540 1260 > 1260
CS640 1260 > 1260

12149 1 02/07/2004
G.10.A / 81

X19. Header 1880
Line: 1880 - 2040
12149 1 02/07/2004
G.10.A / 82
06_53_56_01 1
12149 1 02/07/2004
G.10.A / 83

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

X19. Header 1880
Line: 1880 - 2040
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G.10.A / 84
vfil04cs0013h0a 2
12149 1 02/07/2004
G.10.A / 85
Sensing system Pressure sensor - Short circuit to ground

(G.10.A.95.81 - G.30.B.53)
CS540, CS640, CS520, CS660
E204 - HEADER PRESSURE SENSOR (B18) SHORT TO GROUND OR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty header pressure sensor
Solution:
1. Check the header pressure sensor connector X88 and the in-line harness connectors X24, X26, X111 and
X190.

A. Disconnect connector X88. Check between connector X88 pin A, circuit (088) (BL) and ground. If an

A. Turn the keystart ON. Check between connector X88 pin B, circuit (086) (PK) and ground. If the voltage
indicated is less than +4 Volts, repair or replace the harness as required.

A. Turn the keystart OFF. Disconnect the CCM connector X142. Check between connector X88 pin C,

A. Check between connector X88 pin C, circuit (130) (GE) and X142 pin 5, circuit (130) (GE). If an open
12149 1 02/07/2004
G.10.A / 86

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 87
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 88

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 89
vfil04cs0010h0a 2
12149 1 02/07/2004
G.10.A / 90

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 91
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 92

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 93
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 94
Sensing system Pressure sensor - Short circuit to B+ (G.10.A.95.81

- G.30.B.54)
CS540, CS640, CS520, CS660
E205 - HEADER PRESSURE SENSOR (B18) SHORT CIRCUIT TO +VE
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty header pressure sensor
Solution:
1. Check the header pressure sensor connector X88, CCM connector X142, and the in-line harness connectors
X24, X26, and X111.

A. Disconnect connector X88. Turn the keystart ON. Measure the voltage between connector X88 pin B,
harness as required. If the fault is still present, download the correct level of software. If the fault

A. Turn the keystart OFF. Disconnect connector X142. Turn the keystart ON. Check between connector X88
pin C, circuit (130) (GE) and ground. If a voltage is indicated, repair or replace the harness as required.
B. If the harness is okay, remove and replace the header pressure sensor. If the fault is still present,

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

12149 1 02/07/2004
G.10.A / 95

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 96
55_a3cs009 1
12149 1 02/07/2004
G.10.A / 97

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 98
vfil04cs0010h0a 2
12149 1 02/07/2004
G.10.A / 99

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 100
vfil04cs0011h0a 3
12149 1 02/07/2004
G.10.A / 101

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12149 1 02/07/2004
G.10.A / 102
vfil04cs0012h0a 4
12149 1 02/07/2004
G.10.A / 103
Index
LIFTING - 10.A

CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Command Header resume switch - Short circuit to ground (G.10.A.05.83 - G.30.B.53) 31
CS540, CS640, CS520, CS660
Command valve Header lift valve - Install (G.10.A.12.20 - F.10.A.15) 11
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Command valve Header lift valve - Remove (G.10.A.12.20 - F.10.A.10) 10
CS540, CS640, CS520, CS660
Control valve - Dynamic description (G.10.A.13 - C.30.A.10) 6
CS540, CS640, CS520, CS660
Control valve - Open circuit (G.10.A.13 - G.30.B.50) 58
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Electronic control - Short circuit to ground (G.10.A.92 - G.30.B.53) 67
CS540, CS640, CS520, CS660
Sensing system Height sensor - Short circuit to B+ (G.10.A.95.80 - G.30.B.54) 81
CS540, CS640, CS520, CS660
Sensing system Height sensor - Short circuit to ground (G.10.A.95.80 - G.30.B.53) 76
CS540, CS640, CS520, CS660
Sensing system Pressure sensor - Short circuit to B+ (G.10.A.95.81 - G.30.B.54) 95
CS540, CS640, CS520, CS660
Sensing system Pressure sensor - Short circuit to ground (G.10.A.95.81 - G.30.B.53) 86
CS540, CS640, CS520, CS660
12149 1 02/07/2004
G.10.A / 104
LEVELLING - 30.A
CS540
CS640
CS520
CS660
12150 1 02/07/2004
G.30.A / 1
Contents
LEVELLING - 30.A
FUNCTIONAL DATA
Control valve
CS540, CS640, CS520, CS660
Hydraulic pump
Hydraulic pump - Exploded view (G.30.A.25 - C.10.A.20) 4
CS540, CS640, CS520, CS660
Cylinder
CS540, CS640, CS520, CS660
SERVICE
Cylinder
CS540, CS640, CS520, CS660
DIAGNOSTIC
Command valve
Command valve - Open circuit (G.30.A.12 - G.30.B.50) 8
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Sensing system
Sensing system Position sensor - Short circuit to ground (G.30.A.95.81 - G.30.B.53) 26
CS540, CS640, CS520, CS660
Sensing system Position sensor - Short circuit to B+ (G.30.A.95.81 - G.30.B.54) 31
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Sensing system Latfloat switch - Short circuit to ground (G.30.A.95.80 - G.30.B.53) 46
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
12150 1 02/07/2004
G.30.A / 2
TOOL POSITIONING - LEVELLING
Control valve - Static description (G.30.A.13 - C.30.A.20)

CS540, CS640, CS520, CS660
The pressure valve (30) in the line will open when moving the header laterally with the left-hand side down.
ZDA6268C 1
The pressure in the line towards the main hydraulic valve will be 60 bar (870 psi) at that moment.
ZDF0546A 2
When moving the header laterally with the left-hand side up, full oil flow is possible through the pressure relief valve.
ZDF0547A 3
12150 1 02/07/2004
G.30.A / 3
Hydraulic pump - Exploded view (G.30.A.25 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDF0841A 1
Lateral float hydraulic pump
1 Bearing end plate 2 Pump housing

3 Bearing 4 O-ring
5 Driver 6 Toothed gear
7 Toothed gear 8 Plain washer
9 Nut 10 Bolt
11 Closing cover 12 Protective cap
13 Protective cap 14 Set of seals
NOTE: Tighten the screw (9) with a torque between 22 - 27 Nm. (16 - 20 lb ft)
12150 1 02/07/2004
G.30.A / 4
Cylinder - Sectional view (G.30.A.26 - C.10.A.30)

CS540, CS640, CS520, CS660
CAUTION
1
Lateral flotation cylinder

5 Seal 6 Seal
7 Guide ring 8 Seal
9 Cylinder 10 Bolt (torque 91-111 Nm)
11 Locking wire
12150 1 02/07/2004
G.30.A / 5
Cylinder - Service instruction (G.30.A.26 - F.10.A.05)

CS540, CS640, CS520, CS660
"Lateral float cylinder with a locking wire"
Proceed as follows:
1. Turn the cylinder head (1) using a tool with thread

(see fig.2), until the end of the locking wire (2) is
visible through the gap.
ZDF0727A 1
2. Pull out the locking wire (2) with a screwdriver while

turning the cylinder head (1).
ZDF0725A 2
ZDF0726A 3
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G.30.A / 6

ZDF0735A 4
5. Before reassemble, clean and oil the piston rod (3),

the cylinder sleeve (5) and the seals.
ZDF0735A_73 5
6. Slide the cylinder head (1) with the piston rod into
the cylinder housing and line up the groove for the
locking wire (2).
Turn the cylinder until the cavity provided in the
cylinder becomes visible.
ZDF0727A 6
7. Introduce the folded end of the locking wire (2) in

the cavity, making sure that the other end points to
the bevelled edge of the cylinder slot.
Turn the cylinder head (1) until the locking wire (2)
has been completely pulled into the groove.
ZDF0725A_74 7
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G.30.A / 7
Command valve - Open circuit (G.30.A.12 - G.30.B.50)

CS540, CS640, CS520, CS660
E331 - LATERAL FLOAT RIGHT HAND SIDE UP (COUNTER-CLOCKWISE) PWM OUTPUT OPEN OR SHORT
CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty lateral float solenoid (right hand side up)
Solution:
1. Check the lateral float solenoid connector Y16, CCM connector X141, and the in-line harness connectors
X40, X48 and X190.

X141 pin 14, circuit (141) (GR) and ground. If a voltage is indicated, repair or replace the harness as
required.

A. Turn the keystart OFF. Disconnect the lateral float solenoid connector Y16. Check between connector
X141 pin 14, circuit (141) (GR) and ground. If a short to ground is indicated, repair or replace the

A. Check between connector X141 pin 14, circuit (141) (GR) and connector Y16 pin 2, circuit (141) (GR). If

B. If the harness is okay, remove and replace the lateral float right up solenoid. If the fault is still present,
12150 1 02/07/2004
G.30.A / 8

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 9
55_a3cs009 1
12150 1 02/07/2004
G.30.A / 10

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 11
vfil04cs0010h0a 2
12150 1 02/07/2004
G.30.A / 12

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 13
vfil04cs0011h0a 3
12150 1 02/07/2004
G.30.A / 14

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 15
vfil04cs0012h0a 4
12150 1 02/07/2004
G.30.A / 16
Command valve - Open circuit (G.30.A.12 - G.30.B.50)

CS540, CS640, CS520, CS660
E332 - LATERAL FLOAT LEFT HAND SIDE UP (CLOCKWISE) PWM OUTPUT OPEN OR SHORT CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty lateral float solenoid (left hand side up)
Solution:
1. Check the lateral float solenoid connector Y17, CCM connector X141, and the in-line harness connectors
X40, X48 and X190.

X141 pin 3, circuit (142) (WT) and ground. If a voltage is indicated, repair or replace the harness as
required.

A. Turn the keystart OFF. Disconnect the lateral float solenoid connector Y17. Check between connector
X141 pin 3, circuit (142) (WT) and ground. If a short to ground is indicated, repair or replace the


B. If the harness is okay, remove and replace the lateral float left up solenoid. If the fault is still present,
12150 1 02/07/2004
G.30.A / 17

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 18
55_a3cs009 1
12150 1 02/07/2004
G.30.A / 19

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 20
vfil04cs0010h0a 2
12150 1 02/07/2004
G.30.A / 21

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 22
vfil04cs0011h0a 3
12150 1 02/07/2004
G.30.A / 23

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 24
vfil04cs0012h0a 4
12150 1 02/07/2004
G.30.A / 25
Sensing system Position sensor - Short circuit to ground

(G.30.A.95.81 - G.30.B.53)
CS540, CS640, CS520, CS660
E301 - LEFT HAND SIDE AUTOFLOAT POSITION SENSOR (R8) SHORT TO GROUND OR OPEN CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty autofloat position sensor
Solution:
1. Check the LH side autofloat position sensor connector, CCM connector X142, and the in-line harness
connectors X19, X111, X112 and X163.

A. Disconnect the LH side autofloat position sensor connector. Check between LH side autofloat position
sensor connector pin 1, circuit (160) (BL) and ground. If an open circuit is indicated, repair or replace the

A. Turn the keystart ON. Measure the voltage between LH side autofloat position sensor connector pin 3,
circuit (161) (PK) and ground. If the voltage indicated is less than +4 Volts, repair or replace the

A. Turn the keystart OFF. Disconnect the CCM connector X142. Check between LH side autofloat
position sensor connector pin 2, circuit (147) (GE) and ground. If a short to ground is indicated, repair

A. Check between LH side autofloat position sensor connector pin 2, circuit (147) (GE) and X142 pin 37,
circuit (147) (GE). If an open circuit is indicated, repair or replace the harness as required.
B. If the harness is okay, remove and replace the LH side autofloat position sensor connector. If the fault is
still present, download the correct level of software. If the fault re-occurs, remove and replace the CCM.
12150 1 02/07/2004
G.30.A / 26

(A.30.A - C.20.E.07)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 1880
Line: 1880 - 2040
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G.30.A / 27
06_53_56_01 1
12150 1 02/07/2004
G.30.A / 28

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

X19. Header 1880
Line: 1880 - 2040
12150 1 02/07/2004
G.30.A / 29
vfil04cs0013h0a 2
12150 1 02/07/2004
G.30.A / 30
Sensing system Position sensor - Short circuit to B+ (G.30.A.95.81

- G.30.B.54)
CS540, CS640, CS520, CS660
E302 - LEFT HAND SIDE AUTOFLOAT POSITION SENSOR (R8) SHORT CIRCUIT TO +VE
operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the LH side autofloat position sensor connector, CCM connector X142, and the in-line harness

A. Disconnect LH side autofloat position sensor connector. Turn the keystart ON. Measure the voltage
between LH side autofloat position sensor connector pin 3, circuit (161) (PK) and ground. If the voltage
indicated is greater than +5 Volts, repair or replace the harness as required. If the fault is still present.
Download the correct level of software. If the fault re-occurs, remove and replace the CCM.

A. Turn the keystart OFF. Disconnect the CCM connector X142. Turn the keystart ON. Measure the voltage
between LH side autofloat position sensor connector pin 2, circuit (147) (GE) and ground. If a voltage is

(A.30.A - C.20.E.07)
CS540 1260 > 1260
CS640 1260 > 1260

12150 1 02/07/2004
G.30.A / 31

X19. Header 1880
Line: 1880 - 2040
12150 1 02/07/2004
G.30.A / 32
06_53_56_01 1
12150 1 02/07/2004
G.30.A / 33

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

X19. Header 1880
Line: 1880 - 2040
12150 1 02/07/2004
G.30.A / 34
vfil04cs0013h0a 2
12150 1 02/07/2004
G.30.A / 35

(G.30.A.95.81 - G.30.B.53)
CS540, CS640, CS520, CS660
E304 - RIGHT HAND SIDE AUTOFLOAT POSITION SENSOR (R9) SHORT TO GROUND OR OPEN CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the RH side autofloat position sensor connector, CCM connector X142, and the in-line harness

A. Disconnect the RH side autofloat position sensor connector. Check between RH side autofloat position
sensor connector pin 1, circuit (160) (BL) and ground. If an open circuit is indicated, repair or replace the

A. Turn the keystart ON. Measure the voltage between RH side autofloat position sensor connector pin 3,
circuit (161) (PK) and ground. If the voltage indicated is less than +4 Volts, repair or replace the

A. Turn the keystart OFF. Disconnect the CCM connector X142. Check between RH side autofloat
position sensor connector pin 2, circuit (148) (GE) and ground. If a short to ground is indicated, repair

A. Check between RH side autofloat position sensor connector pin 2, circuit (148) (GE) and X142 pin 38
circuit (148) (GE). If an open circuit is indicated, repair or replace the harness as required.
12150 1 02/07/2004
G.30.A / 36

(A.30.A - C.20.E.07)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 1880
Line: 1880 - 2040
12150 1 02/07/2004
G.30.A / 37
06_53_56_01 1
12150 1 02/07/2004
G.30.A / 38

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

X19. Header 1880
Line: 1880 - 2040
12150 1 02/07/2004
G.30.A / 39
vfil04cs0013h0a 2
12150 1 02/07/2004
G.30.A / 40

(G.30.A.95.81 - G.30.B.53)
CS540, CS640, CS520, CS660
E305 - RIGHT HAND SIDE AUTOFLOAT POSITION SENSOR (R9) SHORT CIRCUIT TO +VE
operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the RH side autofloat position sensor connector, CCM connector X142, and the in-line harness
connectors X19, X111 and X163.

A. Disconnect RH side autofloat position sensor connector. Turn the keystart ON. Measure the voltage
between LH side autofloat position sensor connector pin 3, circuit (161) (PK) and ground. If the voltage
indicated is greater than +5 Volts, repair or replace the harness as required. If the fault is still present.
Download the correct level of software. If the fault re-occurs, remove and replace the CCM.

A. Turn the keystart OFF. Disconnect the CCM connector X142. Turn the keystart ON. Measure the voltage
between RH side autofloat position sensor connector pin 2, circuit (148) (GE) and ground. If a voltage is
B. If the harness is okay, remove and replace the RH side autofloat position sensor connector. If the fault is

(A.30.A - C.20.E.07)
CS540 1260 > 1260
CS640 1260 > 1260

12150 1 02/07/2004
G.30.A / 41

X19. Header 1880
Line: 1880 - 2040
12150 1 02/07/2004
G.30.A / 42
06_53_56_01 1
12150 1 02/07/2004
G.30.A / 43

CS520 1376 > ....
CS540 1320 > ....
CS640 1320 > ....
CS660 1376 > ....

X19. Header 1880
Line: 1880 - 2040
12150 1 02/07/2004
G.30.A / 44
vfil04cs0013h0a 2
12150 1 02/07/2004
G.30.A / 45
Sensing system Latfloat switch - Short circuit to ground

(G.30.A.95.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E321 - LATERAL FLOAT LEFT HAND SIDE DOWN (COUNTER-CLOCKWISE) SWITCH (S27) SHORT TO
GROUND
operation.
Context:
A short to ground on circuit (138) would blow the fuse F3 when the lateral float left down switch is used.
Cause:
1. Faulty connector
2. Faulty harness
Solution:

A. Disconnect the multifunction handle connector X123 and the CCM connector X141. Check between
connector X141 pin 10, circuit (138) (GR) and ground. If a short to ground is indicated, repair or replace
the CCM.

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

12150 1 02/07/2004
G.30.A / 46

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 47
55_a3cs009 1
12150 1 02/07/2004
G.30.A / 48

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 49
vfil04cs0010h0a 2
12150 1 02/07/2004
G.30.A / 50

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 51
vfil04cs0011h0a 3
12150 1 02/07/2004
G.30.A / 52

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 53
vfil04cs0012h0a 4
12150 1 02/07/2004
G.30.A / 54
Sensing system Latfloat switch - Short circuit to ground

(G.30.A.95.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E322 - LATERAL FLOAT RIGHT HAND SIDE DOWN (CLOCKWISE) SWITCH (S28) SHORT TO GROUND
operation.
Context:
A short to ground on circuit (139) would blow the fuse F3 when the lateral float right down switch is used.
Cause:
1. Faulty connector
2. Faulty harness
Solution:

A. Disconnect the multifunction handle connector X123 and the CCM connector X141. Check between
connector X141 pin 11, circuit (139) (WT) and ground. If a short to ground is indicated, repair or replace
the CCM.

(A.30.A - C.20.E.06)
CS540 1260 > 1260
CS640 1260 > 1260

12150 1 02/07/2004
G.30.A / 55

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 56
55_a3cs009 1
12150 1 02/07/2004
G.30.A / 57

CS540 1320 > 1324
CS640 1320 > 1324

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 58
vfil04cs0010h0a 2
12150 1 02/07/2004
G.30.A / 59

CS540 1364 > 1372
CS640 1364 > 1372

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 60
vfil04cs0011h0a 3
12150 1 02/07/2004
G.30.A / 61

CS520 1376 > ....
CS540 1376 > ....
CS640 1376 > ....
CS660 1376 > ....

Line: 1370 - 1700
12150 1 02/07/2004
G.30.A / 62
vfil04cs0012h0a 4
12150 1 02/07/2004
G.30.A / 63
Index
LEVELLING - 30.A

CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Hydraulic pump - Exploded view (G.30.A.25 - C.10.A.20) 4
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Sensing system Position sensor - Short circuit to B+ (G.30.A.95.81 - G.30.B.54) 31
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
12150 1 02/07/2004
G.30.A / 64
12150 1 02/07/2004
G.30.A / 65
PRINTED IN BELGIUM
12148 1 02/07/2004
REPAIR MANUAL
CROP PROCESSING
CS540
CS640
CS520
CS660
12151 1 02/07/2004
K
Contents
CROP PROCESSING - K
FEEDING Header feeding K.25.D

CS540, CS640, CS520, CS660
FEEDING Feeder housing K.25.E

CS540, CS640, CS520, CS660
FEEDING Reel feeding K.25.B

CS540, CS640, CS520, CS660
THRESHING Conventional threshing K.40.B

CS540, CS640, CS520, CS660
SEPARATING Beating K.42.B

CS540, CS640, CS520, CS660
SEPARATING Rotary separator K.42.C

CS540, CS640, CS520, CS660
SEPARATING Straw walker K.42.E

CS540, CS640, CS520, CS660
CLEANING Primary cleaning K.62.B

CS540, CS640, CS520, CS660
CLEANING Tailings return system K.62.C

CS540, CS640, CS520, CS660
STORING AND HANDLING Grain storing K.60.B

CS540, CS640, CS520, CS660
UNLOADING Grain unloading K.72.B

CS540, CS640, CS520, CS660
RESIDUE HANDLING Straw chopper K.64.C

CS540, CS640, CS520, CS660
PROTECTION SYSTEMS Reversing system K.90.C

CS540, CS640, CS520, CS660
12151 1 02/07/2004
K
CROP PROCESSING - K
FEEDING Header feeding - 25.D
CS540
CS640
CS520
CS660
12152 1 02/07/2004
K.25.D / 1
Contents
CROP PROCESSING - K
FUNCTIONAL DATA
Drive system
Drive system Drive shaft - Exploded view (K.25.D.42.43 - C.10.A.20) 3
CS540, CS640, CS520, CS660
SERVICE
Drive system
Drive system Drive shaft - Remove (K.25.D.42.43 - F.10.A.10) 4
CS540, CS640, CS520, CS660
Drive system Drive shaft - Install (K.25.D.42.43 - F.10.A.15) 7
CS540, CS640, CS520, CS660
12152 1 02/07/2004
K.25.D / 2
CROP PROCESSING - FEEDING Header feeding
Drive system Drive shaft - Exploded view (K.25.D.42.43 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA6971A 1
Header drive shaft (Hydraulic reverser)
1 Header drive shaft 2 Bearing

3 Lock collar 4 Bearing
5 Lock collar 6 Cover
12152 1 02/07/2004
K.25.D / 3
Drive system Drive shaft - Remove (K.25.D.42.43 - F.10.A.10)

CS540, CS640, CS520, CS660
If hydraulic reverser
1. At the left-hand side, raise the straw elevator

completely, install the safety latch (1), and stop the
engine.
WARNING
M184D - ALWAYS shut OFF engine, remove the key
and engage feeder safety lock in position on lift
cylinder before working under header or feeder.
Failure to engage feeder safety lock may cause injury
or death.
ZDA6965A 1
2. Remove the shielding.

3. Remove the header drive belt (2) by loosening the
nuts (4) and (3).
ZDA5931B_126 2
4. Loosen the counter nut (5) and the nut (6).

Remove the pulley (7) from the shaft.
ZDA6967A 3
12152 1 02/07/2004
K.25.D / 4
5. Remove the four bolts (1) of the bearing housing (2).
ZDA6981A 4
6. At the right-hand side, remove the cover (1) by

loosening the four bolts (2).
ZDA7138A 5
7. Loosen the Allen screw to remove the lock collar (2).

Remove the three bolts (3).
Remove the bearing with the flanges.
ZDA6968A 6
8. Now is it possible to remove the header drive shaft

out to from the left-hand side.
ZDA7351A 7
12152 1 02/07/2004
K.25.D / 5
9. To remove the left-hand side bearing (1) from the

header drive shaft (2), remove the two keys (3) and
loosen the Allen screw of the lock collar (4).
ZDA6969A 8
12152 1 02/07/2004
K.25.D / 6
Drive system Drive shaft - Install (K.25.D.42.43 - F.10.A.15)

CS540, CS640, CS520, CS660
If hydraulic reverser
1. Install first the lock collar with the bearing (1) on

left-hand side of the header drive shaft (2) with
dimension “X" between 227 - 229 mm. (8-15/16 -
9-1/64 in)
Grease the lock collar with anti-corrosive grease.
Install the lock collar (4).
Tighten the Allen screw.
ZDA6969A 1
2. Bring the pre-assembled shaft (1) with the grease

hole of the bearing housing downwards into the
straw elevator frame from the left-hand side.
Install the two keys (3).
ZDA6981B 2
3. Install the bearing with the flanges at the right-hand

side and tighten the three bolts (3).
Install the lock collar (2) and tighten the Allen screw.
ZDA6968A 3
12152 1 02/07/2004
K.25.D / 7
4. Install the cover (1) and tighten the bolts (2).
ZDA7138A_127 4
5. At the left-hand side, install the pulley (7) as follows:

2HB: dimension "Y" = between 150 - 154 mm.
(5-29/32 - 6-1/16 in)
3HB: dimension "Z" = between 131 - 135 mm.
(5-5/32 - 5-5/16 in) (This is in line with the pulley
on the upper shaft.)
ZDA6970A 5
6. Tighten the nut (6), with a minimum torque of 240

Nm. (177 lb ft)
Tighten the counter nut (5), with a minimum torque
of 120 Nm. (88.5 lb ft)
Grease the shaft ends with grease NLGI-2.
ZDA6967A 6
7. Install the drive belt (2).
ZDA5931B_118 7
12152 1 02/07/2004
K.25.D / 8
8. Install the shielding.

9. Install the header drive belt and adjust as described
in the CS Operator’s manual. "SECTION 4
-LUBRICATION AND MAINTENANCE",paragraph
headed: “Drive belts and chains".
12152 1 02/07/2004
K.25.D / 9
Index
CROP PROCESSING - K
Drive system Drive shaft - Exploded view (K.25.D.42.43 - C.10.A.20) 3

CS540, CS640, CS520, CS660
Drive system Drive shaft - Install (K.25.D.42.43 - F.10.A.15) 7
CS540, CS640, CS520, CS660
Drive system Drive shaft - Remove (K.25.D.42.43 - F.10.A.10) 4
CS540, CS640, CS520, CS660
12152 1 02/07/2004
K.25.D / 10
CROP PROCESSING - K
FEEDING Feeder housing - 25.E
CS540
CS640
CS520
CS660
12153 1 02/07/2004
K.25.E / 1
Contents
CROP PROCESSING - K
TECHNICAL DATA
Drive shaft
Drive shaft - Dimension (K.25.E.41 - D.40.A.30) 4
CS540, CS520
CS640, CS660
Cradle
Cradle Seal - General specification (K.25.E.77.40 - D.40.A.10) 6
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
Pneumatic cylinder
Pneumatic cylinder - Sectional view (K.25.E.27 - C.10.A.30) 7
CS540, CS640, CS520, CS660
Drive system
Drive system Slip clutch - Exploded view (K.25.E.40.46 - C.10.A.20) 8
CS540, CS640, CS520, CS660
Drive shaft
Drive shaft - Exploded view (K.25.E.41 - C.10.A.20) 9
CS540, CS640, CS520, CS660
Reversing system
Reversing system - Exploded view (K.25.E.42 - C.10.A.20) 10
CS540, CS640, CS520, CS660
Bottom shaft
Bottom shaft - Exploded view (K.25.E.56 - C.10.A.20) 11
CS540, CS640, CS520, CS660
Cradle
Cradle - Exploded view (K.25.E.77 - C.10.A.20) 12
CS540, CS640, CS520, CS660
SERVICE
Pneumatic cylinder
Pneumatic cylinder - Disassemble (K.25.E.27 - F.10.A.25) 13
CS540, CS640, CS520, CS660
Pneumatic cylinder - Assemble (K.25.E.27 - F.10.A.20) 16
CS540, CS640, CS520, CS660
Drive system
12153 1 02/07/2004
K.25.E / 2
Drive system Belt - Remove (K.25.E.40.44 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Drive system Belt - Install (K.25.E.40.44 - F.10.A.15) 22
CS540, CS640, CS520, CS660
Drive system Slip clutch - Disassemble (K.25.E.40.46 - F.10.A.25) 26
CS540, CS640, CS520, CS660
Drive system Slip clutch - Assemble (K.25.E.40.46 - F.10.A.20) 29
CS540, CS640, CS520, CS660
Drive shaft
Drive shaft - Remove (K.25.E.41 - F.10.A.10) 32
CS540, CS640, CS520, CS660
Drive shaft - Install (K.25.E.41 - F.10.A.15) 35
CS540, CS640, CS520, CS660
Reversing system
Reversing system Hydraulic motor - Remove (K.25.E.42.28 - F.10.A.10) 37
CS540, CS640, CS520, CS660
Reversing system Hydraulic motor - Install (K.25.E.42.28 - F.10.A.15) 40
CS540, CS640, CS520, CS660
Feed chain
Feed chain - Remove (K.25.E.48 - F.10.A.10) 43
CS540, CS640, CS520, CS660
Feed chain - Install (K.25.E.48 - F.10.A.15) 44
CS540, CS640, CS520, CS660
Bottom shaft
Bottom shaft - Remove (K.25.E.56 - F.10.A.10) 45
CS540, CS640, CS520, CS660
Bottom shaft - Disassemble (K.25.E.56 - F.10.A.25) 47
CS540, CS640, CS520, CS660
Bottom shaft - Assemble (K.25.E.56 - F.10.A.20) 48
CS540, CS640, CS520, CS660
Bottom shaft - Install (K.25.E.56 - F.10.A.15) 50
CS540, CS640, CS520, CS660
Intermediate plate
Intermediate plate - Remove (K.25.E.75 - F.10.A.10) 52
CS540, CS640, CS520, CS660
Intermediate plate - Install (K.25.E.75 - F.10.A.15) 53
CS540, CS640, CS520, CS660
Cradle
Cradle - Remove (K.25.E.77 - F.10.A.10) 54
CS540, CS640, CS520, CS660
Cradle - Install (K.25.E.77 - F.10.A.15) 56
CS540, CS640, CS520, CS660
Cradle - Replace (K.25.E.77 - F.10.A.30) 58
CS540, CS640, CS520, CS660
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K.25.E / 3
CROP PROCESSING - FEEDING Feeder housing
Drive shaft - Dimension (K.25.E.41 - D.40.A.30)

CS540, CS520
ZDA6621A 1
Straw elevator upper shaft
12153 1 02/07/2004
K.25.E / 4
A = 1314 mm B = 517-519 mm
C = 517-519 mm D = 138-140 mm
Y = 2-3.5 mm (5/64 in - 1/8 in) Z = 3 mm
Drive shaft - Dimension (K.25.E.41 - D.40.A.30)

CS640, CS660
ZDA6622A 1
12153 1 02/07/2004
K.25.E / 5
A = 1574 mm B = 439 mm
C = 836-838 mm D = 378-380 mm
E = 178-180 mm F = 378-380 mm
G = 178-180 mm Y = 2-3.5 mm (5/64 in - 1/8 in)
Z = 3 mm
Cradle Seal - General specification (K.25.E.77.40 - D.40.A.10)

CS540, CS640, CS520, CS660
Specifications
° Cleansing liquid
Base: solvent
Color: color less
Specific weight: 0.757-0.765 g/cm3 at 20 ° C
Flash point: 56 ° C
Kinematic viscosity: 1.42 mm2 /sec at 25 ° C
° Primer
Base: polyisocyanate
Color: Black
Pigment: soot colored
Specific weight: 0.91 g/cm3 +/- 0.02 at 23 ° C
Viscosity (Din head 4): < 16 s at 23 ° C
Flash point: 8 ° C
° Glue
Base: polyurethaneprepolymere
Color: black
Density: 1.23 g/cm3 +/- 0.03 at 23 ° C
Flash point: > 100 ° C
Viscosity by extrusion: 12-20 g/min at 23 ° C
Solid content: > 98 %
Consistency: non sag
Processing temperature: 10-40 ° C
Processing rate: maximum 15 min at 23 ° C / 50 % R.M.
Cure rate: > 4 mm during the first 48 h at 23 ° C / 50 % R.M.
Hardness (DIN 53505): 60+/-5 shore A
Elongation at break (DIN 53504): >500 %
Tensile strength (DIN53504): 9 +/-1 N/mm2
Temperature resistance: -40 - 100 ° C (temporary up to 140 ° C)
Chemical resistance good against aqueous solutions, benzine, alcools, mineral oil.
Characteristics: In accordance with the EG guide-lines for materials and preparations.
- symbol: -
- R-serie: -
- S-serie: 24/25
12153 1 02/07/2004
K.25.E / 6
Pneumatic cylinder - Sectional view (K.25.E.27 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDF0822A 1
Straw elevator engaging cylinder
1 Ring 2-
3- 4-
5- 6 Back part
7 Bushing 8 Ring
9 Allen screw 10 Piston rod stop
11 O-ring 12 Guide ring
13 Cylinder housing 14 Piston rod
15 Bolt 16 Front part
17 Seal 18 Bushing
12153 1 02/07/2004
K.25.E / 7
Drive system Slip clutch - Exploded view (K.25.E.40.46 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA6295A 1
Straw elevator slip clutch
1 Cotter pin 2 Nut

3 Special washer 4 Bolt
5 Ring 6 Bolt
7 Fixing plate 8 Spring
9 Pressure Plate 10 Clutch disc
11 Bushing 12 Washer
13 Shielding 14 Pulley
12153 1 02/07/2004
K.25.E / 8
Drive shaft - Exploded view (K.25.E.41 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA6687A 1
1 Upper shaft (model CS500) 2 Upper shaft (model CS600)

3 Sprocket 4 Bearing housing
5 Bearing 6 Bearing housing (model CS600)
7 Bearing (model CS600) 8 Guard
9 Headed key 10 Key
12153 1 02/07/2004
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Reversing system - Exploded view (K.25.E.42 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDF0847A 1
Hydraulic reverser
1 Hydraulic reverser 2 Hydraulic screw coupler (port "A")

3 Hydraulic screw coupler (port "B") 4 Reverser support
5 Cotter pin 6 Castle nut
7 Washer 8 Pulley
9 Key 10 Bolt
12153 1 02/07/2004
K.25.E / 10
Bottom shaft - Exploded view (K.25.E.56 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7326A 1
Bottom shaft
1 Lower shaft (model CS500) 2 Lower shaft (model CS600)

3 Central shaft 4 Bearing
5 Flange 6 Bolt
12153 1 02/07/2004
K.25.E / 11
Cradle - Exploded view (K.25.E.77 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7541A 1
Cradle
1 Cradle 2 Anti-dust plate

3 Central axle 4 Shim pack
5 Support 6 Sealing
7 Bolt 8 Coach bolt
9 Spacer key 10 Washer
11 Locknut
12153 1 02/07/2004
K.25.E / 12
Pneumatic cylinder - Disassemble (K.25.E.27 - F.10.A.25)

CS540, CS640, CS520, CS660
1. Remove the header engaging cylinder.

Loosen the hose clamp (1) to disconnect the cover
(2) from the cylinder housing.
Loosen the four Allen screws (3) to remove the
support (4).
ZDF0742A 1
2. To remove the back part (6) of the cylinder loosen

the four bolts (5).
ZDF0744A 2
3. Take the end cap washer (7) out of the back part (6).
ZDF0745A 3
12153 1 02/07/2004
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4. Remove the cushioning seal (8) from the end cap

washer (7).
ZDF0746A 4
5. Loosen the Allen screw (9) and remove the piston

rod stop (10). (To loosen the Allen screw, use a
extra wrench as shown)
ZDF0747A 5
6. Remove the O-ring (11).
ZDF0752A 6
7. Remove the cylinder guide ring (12).
ZDF0748A 7
12153 1 02/07/2004
K.25.E / 14
8. Now is it possible to slide the piston rod (14) out of

the cylinder housing (13).
ZDF0749A 8
9. Remove the front part (16) of the cylinder housing

by loosening the four bolts (15).
ZDF0750A 9
10. Take the cushioning seal (17) out of the end cap
washer (18).
Remove the end cap washer (18) from the cylinder
housing.
ZDF0751A 10
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K.25.E / 15
Pneumatic cylinder - Assemble (K.25.E.27 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Install the end cap washer (18) onto the front part
of the cylinder housing.
Install the cushioning seal (17) in the right position.
ZDF0751A_78 1
2. Bring the front part (16) in place and install the four
bolts (15).
ZDF0750A_79 2
3. Check if the cover (2) and the hose clamp (1) are
installed onto the piston rod (14).
ZDF0743A 3
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K.25.E / 16
4. Slide the piston rod (14) into the cylinder housing

(13).
ZDF0749A_80 4
5. Insert the guide ring (12) onto the piston rod in the
cylinder housing.
ZDF0739A 5
6. Install the O-ring (11) onto the guide ring.
ZDF0752A_81 6
7. Install the ring (1) and the Allen screw (9) onto the
piston rod stop (10).
ZDF0740A 7
12153 1 02/07/2004
K.25.E / 17
8. Install the pre-assembled piston rod stop (10) onto

the cylinder and tighten with the Allen screw (9).
ZDF0741A 8
9. Install the cushioning seal (8) with the end cap

washer (7) onto the rear end (6) of the cylinder
housing.
ZDF0745B 9
10. Install the pre assembled rear end (6) onto the
cylinder with the four bolts (5).
ZDF0744A_82 10
11. Install the support (4) and tighten the four Allen
screws (3).
Install the cover (2) in place and tighten the hose
clamp (1).
ZDF0742A_83 11
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K.25.E / 18
Drive system Belt - Remove (K.25.E.40.44 - F.10.A.10)

CS540, CS640, CS520, CS660
1. At the left-hand side of the straw elevator, remove

the shielding (1) and (2), using the special tool that
is located at the left-hand side of the straw elevator.
ZDA6149A_115 1
2. Open the left-hand side shielding at the combine.

Remove the cover (3).
ZDA6150A 2
3. Loosen the nut (1) to release the main drive belt.
ZDA5937B 3
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4. Remove the main drive belt (2) from the pulley.
ZDA6257B 4
5. Loosen the three bolts (1) to remove the pulley (2).
ZDA7230A 5
6. Remove the three bolts (3) of the support (4).
ZDA7231A 6
7. Remove the two bolts (5) at the front and remove

the belt guide (6) of the straw elevator drive belt
completely.
ZDA7232A 7
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K.25.E / 20
8. Loosen the bolt (7) to remove the idler and the belt
hook.
ZDA7233A 8
9. Remove the straw elevator drive belt (1).
ZDA7234A 9
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K.25.E / 21
Drive system Belt - Install (K.25.E.40.44 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the new belt (1).
ZDA7234A 1
2. Install the washers, the belt hook (2), the idler (3)
and the washer with the bolt (4).
ZDA7329A 2
3. Install the belt guide (6) of the straw elevator drive

belt at the front with the two bolts (5). Do not tighten
the bolts (5).
ZDA7232A_116 3
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K.25.E / 22
4. Install the support (4) with the belt guide at the rear
and tighten the three bolts (3).
ZDA7231A 4
5. Engage the header system (without starting the

engine) by turning the button (1) of the pneumatic
valve a quarter clockwise, that is located at the
left-hand side above the battery key.
ZDA6611D_117 5
6. If the combine is equipped with a pneumatic valve

as shown (from series 1376): Press onto the screw
(2) and turn it a quarter clockwise, using a screw
driver.
ZEIL04CS0055A0C 6
7. Adjust the belt hook (2) so that the gap "Y" is even
on both sides.
IMPORTANT: Check, if there is no interference between
the belt and the belt hook (2) when the belt is engaged.
ZDA7329B 7
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K.25.E / 23
8. Adjust the belt guide so that the dimension "X" on

the nearest place is between 5 - 7 mm. (3/16 - 1/4
in)
After adjusting, tighten all the bolts of the straw
elevator belt guide.
ZDA7257A 8
9. Install the support (3) and tighten it with the two

bolts.
The distance between the support (3) and the drive
belt should be 4 - 8 mm. (5/32 - 10/32 in)
Release the straw elevator drive belt tensioner by
turning the button (or screw) on the pneumatic valve
a quarter counter clockwise .
ZEIL04CS0080A0B 9
10. Install the pulley (2) and tighten the three bolts (1).
ZDA7230A 10
11. Install the main drive belt (2).
ZDA6257B 11
12153 1 02/07/2004
K.25.E / 24
12. Adjust the belt tension by tighten the nut (1).

Refer to the CS Operator’s Manual: SECTION 4 -
LUBRICATION AND MAINTENANCE"; paragraph
headed: “Drive belts and chains".
ZDA5937B 12
13. Install the guards (1) and (2).
ZEIL04CS0081A0B 13
14. Install the shielding (2) and (1).
ZDA6149A_115 14
12153 1 02/07/2004
K.25.E / 25
Drive system Slip clutch - Disassemble (K.25.E.40.46 - F.10.A.25)

CS540, CS640, CS520, CS660
1. To remove the slip clutch, detach the straw elevator,

refer to the CS Operator’s Manual; "SECTION
3 - “FIELD AND SITE OPERATION", paragraph
headed: "Straw elevator - Removal and Installation".
NOTE: It’s also possible to first remove the left-hand side
traction wheel.
2. Remove the header drive belt (2) by loosening the
nuts (4) and (3).
ZDA5931B_118 1
3. Loosen the four bolts to remove the shielding (13)

of the pulley.
ZDA6620A 2
4. Remove the cotter pin (1), the nut (2) and the
special washer (3).
ZDA6288A_119 3
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K.25.E / 26
5. Remove the slip clutch completely, using a puller.
ZDA6289A_120 4
6. Remove the four bolts (4) to remove the ring (5).
ZDA6290A 5
7. Loosen the eight bolts (6), evenly one turn at a time

to remove spring pressure from the clutch. Remove
the fixing plates (7) and the springs (8) from the
back of the pulley (14).
Remove the pressure plate (9) from the sheave.
ZDA6293A 6
8. Remove the clutch discs (10).
ZDA6291A 7
12153 1 02/07/2004
K.25.E / 27
9. Slide the bushing (11) out of the pulley. Be careful,

there are three washers (12) between the bushing
and the pulley.
ZDA6294A 8
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K.25.E / 28
Drive system Slip clutch - Assemble (K.25.E.40.46 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Install the three washers (12) over the bushing (11)

and install the bushing assembly into the pulley.
NOTE: Grease the bushing (11) and the eight bolts (6)
(fig.3) with anti-corrosive grease. Grease the clutch discs
(10) (fig.2) and the three washers (12) with grease NLGI-2.
ZDA6294A 1
2. Install the clutch disc (10) on the bushing (11), (fig.1)

and the pressure plate 9 (fig.3). Ensure the pins on
the clutch discs are properly seated in the holes in
the bushing and pressure plate.
ZDA6291A 2
3. Insert the eight bolts (6) through the pressure plate

(9) and the pulley (14). Install a spring (8) over each
bolt, and install the fixing plates (7), by threading
the bolts into them.
NOTE: The fixing plates must be installed into spring pairs
between the pulley spokes.
ZDA6293A_121 3
12153 1 02/07/2004
K.25.E / 29
4. Tighten the bolts evenly one turn at a time and

adjust the springs (8) to distance "Y" (spring length)
= 37-39 mm (1-1/2 in - 1-17/32 in).
ZDA6296A 4
5. Install the ring (5) with the four bolts (4).

NOTE: Turn the eight bolts (6), (fig3), until it is possible
to install the ring (5).
ZDA6290A_122 5
12153 1 02/07/2004
K.25.E / 30
6. Install the assembled slip clutch to the upper shaft.

Install the special washer (3) and tighten the nut (2)
with a maximum torque of 80 Nm (59 lb ft.).
IMPORTANT: Do not turn slotted nut back when mounting
the cotter pin.
ZDA6288A_123 6
7. Install the shielding (13).

NOTE: Install the shielding with hole on grease zerk.
ZDA6620A 7
8. Grease the slip clutch.

9. Install the drive belt (2).
Adjust the belt with the nut (3), refer to the CS
Operator’s Manual; “SECTION 4 - LUBRICATION
AND MAINTENANCE".
Tighten the counter nut (4) with a minimum torque
of 120 Nm. (88.5 lb ft)
ZDA5931B_118 8
10. Attach the straw elevator, refer to the CS

Operator’s Manual; “SECTION 3 - FIELD AND SITE
OPERATION". paragraph headed: “Straw elevator -
Removal and Installation".
12153 1 02/07/2004
K.25.E / 31
Drive shaft - Remove (K.25.E.41 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Detach the straw elevator. Refer to the CS

Operator’s Manual: “SECTION 3 - FIELD AND SITE
OPERATION": paragraph headed: “Straw elevator -
2. Open the elevator chain. Refer to Feed chain -
Remove (K.25.E.48 - F.10.A.10).
NOTE: It is not necessary to remove the straw elevator
chain.
3. Fit a rope to the lower and upper chain end to hold
the chain.
4. Loosen the four bolts to remove the shielding (13)
of the pulley.
ZDA6292A 1
5. Remove the cotter pin (1), the nut (2) and the
special washer (3).
ZDA6288A 2
6. Remove the slip clutch completely with a puller.
ZDA6289A 3
12153 1 02/07/2004
K.25.E / 32
7. Remove the key of the slip clutch on the upper shaft.

8. Remove the anti-wrap shields (4).
ZDA3358A 4
9. Model CS600 only: Loosen the Allen screw of the

lock collar (1) of the centre bearing and loosen the
two bolts (2) to remove the bearing housing from
the cross beam.
ZDA3456A 5
10. Remove the headed keys (5).
ZDA3359A 6
12153 1 02/07/2004
K.25.E / 33
11. Remove the two grease lines (1) from the bearing
housing (2) on both sides.
Remove the central bolt (3) and the washer on the
right-hand side.
Remove the bolts (4), to remove bearing housing,
(2) on both sides.
Slide the shaft to the right-hand side until it is free
on the left side, take the shaft out of the straw
elevator casing.
Remove the sprockets and the guards from the
shaft.
ZDA6980A 7
12153 1 02/07/2004
K.25.E / 34
Drive shaft - Install (K.25.E.41 - F.10.A.15)

CS540, CS640, CS520, CS660
Refer to Drive shaft - Dimension (K.25.E.41 - D.40.A.30).
1. Install the felt ring (1) with grease NLGI-2 on both

sides in the bearing housing.
2. Install the bearing housing with the bearing (2) loose
on the left-hand side of the straw elevator casing.
NOTE: Install the bearing with the marked side on outside
of the straw elevator.
3. Install the bearing housing without the bearing (2)
loose on the right-hand side of the straw elevator
casing.
4. Slide the guards (3) and the sprockets (4) on the
shaft.
5. Model CS600 only: Slide also the bearing (5) with
the lock collar loose on the shaft. (grease the inner
ring and collar with anti corrosive grease and the
sealing with grease NLGI-2).
6. Introduce the shaft from the middle to the right-hand
side in the straw elevator casing and then slide it
to the left.
7. Move the left-hand side bearing (2) against the stop
on the shaft.
8. Install the right-hand side bearing (2) with the plate
(6) and tighten the bolt (7).
IMPORTANT: Do not hammer the bearings on the upper
shaft.
9. Tighten the bearing housing bolts (8) crosswise on
both sides with a minimum torque of 45 Nm (33 lb
ft.).
10. Install the grease lines on both sides.
11. Install the sprockets (4) with the headed keys.
Refer to Drive shaft - Dimension (K.25.E.41 -
D.40.A.30). (Dimensions are marked.)
NOTE: Install the headed key in according to mark on the
sprocket and lock them with two punch marks.
12153 1 02/07/2004
K.25.E / 35
12. Model CS600 only: Install the bearing housing

and the centre bearing (5) on the cross beam and
secure the lock collar.
13. Install the anti-wrap plates (10) on both sides
(clearance 0 mm on nearest place of the upper
shaft).
14. Install the key (13) on the left-hand side of the upper
shaft.
15. Grease the shaft end with grease NLGI-2.
16. Install the slip clutch.
17. Install the washer (11) and tighten the nut (12) with
a maximum torque of 80 Nm (59 lb ft.).
18. Install the cotter pin.
IMPORTANT: Do not turn slotted nut back when mounting
cotter pin.
19. Install the anti-wrap shields and tighten the bolts
foreseen with loctite with a minimum torque of 28
Nm (21 lb ft.).
IMPORTANT: The sprockets must turn freely.
ZDA6264A 1
20. Install the straw elevator chain. Refer to Feed chain

- Install (K.25.E.48 - F.10.A.15).
12153 1 02/07/2004
K.25.E / 36
Reversing system Hydraulic motor - Remove (K.25.E.42.28 -

F.10.A.10)
CS540, CS640, CS520, CS660
1. Disconnect the hydraulic hoses as shown by the

arrows.
IMPORTANT: Avoid possible oil contamination by properly
fitting the blanking plugs into the hydraulic quick couplers.
ZDA6258A 1
2. At the left-hand side, remove the shielding (1) and

(2), using the special tool.
ZDA6149A 2
3. Engage the header system (without starting the

engine) by turning the button (1) of the pneumatic
valve 1/4 turn clock wise, located at the left-hand
side above the battery key.
CAUTION
Z014 - For safety raisons, make sure nobody is near
the combine when engaging or disengaging the
valve(s), even when the engine is not running!
ZDA6611D 3
12153 1 02/07/2004
K.25.E / 37
4. If the combine is equipped with a pneumatic valve

as shown (from series 1376): Press onto the screw
(2) and turn it a quarter clockwise, using a screw
driver.
ZEIL04CS0055A0C 4
5. Remove the cotter pin (5).

Loosen the castle nut (6).
ZDF0761A 5
6. Remove the header drive belt by (2) by loosening

the nuts (4) and (3).
NOTE: Mark the routing of the drive belt (2) before
removal.
ZDA5931B 6
7. Remove the castle nut (6) completely and the

washer (7).
ZDF0825A 7
12153 1 02/07/2004
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8. Remove the pulley (8), using a puller.
ZDF0839A 8

Loosen the four bolts (10). Now is it possible to
remove the hydraulic reverser completely.
ZDF0840A 9
12153 1 02/07/2004
K.25.E / 39
Reversing system Hydraulic motor - Install (K.25.E.42.28 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the hydraulic reverser in place.
ZDF0808A 1
2. Install and tighten the four bolts (10).

ZDF0840A_64 2
3. Install the pulley.

Install the washer (7) and the castle nut (6).
ZDF0825A_65 3
12153 1 02/07/2004
K.25.E / 40
4. Install the header drive belt (2) and tighten the

nuts (3) and (4). To adjust the header drive belt,
refer to the CS Operator’s manual: “SECTION 4 -
LUBRICATION AND MAINTENANCE“: paragraph
headed: “Belts and Chains".
ZDA5931B 4
5. Tighten the castle nut (6) with a minimum torque of

165 Nm.(122 lb ft)
Turn the castle nut (6) further until the cotter pin
(5) can be installed.
ZDF0761A 5
6. Disengage the header system (without starting the

engine) by turning the button (or screw) on the
pneumatic valve 1/4 turn counter clock wise.
7. At the left-hand side of the straw elevator, install the
shielding (2) and (1), using the special tool.
ZDA6149A 6
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K.25.E / 41
8. Connect the hydraulic hoses.
ZDA6258A 7
12153 1 02/07/2004
K.25.E / 42
Feed chain - Remove (K.25.E.48 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Detach the straw elevator from the combine. Refer

to the CS Operator’s Manual: “SECTION 3 - FIELD
AND SITE OPERATION". paragraph headed:
“Straw elevator - Removal and Installation".
2. Release the chain tension by loosening the nut (1)
on both sides.
ZDA5929C 1
3. Rotate the elevator chain until the chain coupler

links are accessible on the top shaft side and open
the joining links.
4. Fit a rope to the lower part of the chain at the two
outer links.
NOTE: To install a complete new straw elevator chain,
fit the new straw elevator chain to the lower links of the
chain to be removed.
ZDA7301A 2
5. Pull the straw elevator chain over the top shaft out
of the straw elevator. Hold the two ropes (or new
straw elevator chain) with a little tension to prevent
the chain from sliding fast to the bottom of the straw
elevator housing.
12153 1 02/07/2004
K.25.E / 43
Feed chain - Install (K.25.E.48 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Attach the ropes to the new straw elevator chain and

pull the chain underneath the top shaft to the bottom
shaft. Pull the chain over the bottom shaft to the top.
NOTE: This job should be done with at least two people.
NOTE: Be sure the straw elevator chain is in the right
direction. The straight edge should be towards the
direction of travel.
ZDA7521A 1
2. Close the new chain with the coupler links (1).

NOTE: Insert the coupler links from the same side of the
guide on the guide wheel on the bottom shaft (the cotter
pins should be in the opposite side of the chain then the
edges of the discs on the lower shaft).
ZDA7301B 2
3. Install the cotter pins (2) to secure the coupler links.

NOTE: Insert the cotter pins in the direction of travel (as
shown) and bend the legs close to the pen.
4. Move the straw elevator chain as much as possible
to the right-hand side while turning the chain a few
times around.
On the left-hand side, tighten the spring (2)
completely.
On the right-hand side, tighten the spring (2)
completely and then adjust to the length of the
indicator plate.
On the left-hand side, adjust the spring (2) to the
length of the indicator plate (3).
ZDA5929F 3
12153 1 02/07/2004
K.25.E / 44
Bottom shaft - Remove (K.25.E.56 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the anti dust plate (1).
ZDA6623A 1
2. Rotate the straw elevator chain until the chain

coupler links (2) are accessible on the bottom shaft
side.
ZDA6624A 2
3. Loosen the nuts (1) and (2) on both sides.

Remove the spring (3), the bushing and the bolt (4)
completely from the right-hand side.
Disconnect the joining links on the straw elevator
chain. (fig.2)
ZDA5929E 3
12153 1 02/07/2004
K.25.E / 45
4. Loosen the jam nut (1) and the bolt (2) on both sides
of the bottom shaft.
ZDA6625A 4
5. Remove the jam nut (5) and the nut (6).

At the right-hand side, remove the support (7)
completely.
ZDA5929D 5
6. Slide the bottom shaft (1) out to the right of the

left-hand side support.
ZDA6626A 6
12153 1 02/07/2004
K.25.E / 46
Bottom shaft - Disassemble (K.25.E.56 - F.10.A.25)

CS540, CS640, CS520, CS660
Prior operation: Refer to Bottom shaft - Remove (K.25.E.56 - F.10.A.10).
1. Loosen the Allen screw (1) to remove the lock collar

(2) on both sides.
ZDA6639A 1
2. Remove the three bolts (3) to remove the bearing

flange.
Remove the bearing (4).
ZDA6638A 2
3. Slide the shaft (5) out of the bottom shaft.
ZDA6640A 3
12153 1 02/07/2004
K.25.E / 47
Bottom shaft - Assemble (K.25.E.56 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Bring the shaft (5) into the bottom shaft.
ZDA6640A_124 1
2. Install the bearing (4) with the bearing flange.

Install and tighten the three bolts (3).
ZDA6638A_125 2
3. Adjust the shaft in the lower shaft with the

dimensions "X" between 71 - 75 mm. (2-3/4 in -
3 in)
CS500 model: fig.3
ZDA6685A 3
12153 1 02/07/2004
K.25.E / 48
4. Adjust the shaft in the lower shaft with the

dimensions “X" between 71 - 75 mm. (2-3/4 in -
3 in)
CS600 model: fig.4
ZDA6686A 4
5. After adjusting the shaft, install the lock collar (2)

and tighten the Allen screw (1) on both sides.
ZDA6639A 5
Next operation: Refer to Bottom shaft - Install (K.25.E.56 - F.10.A.15).
12153 1 02/07/2004
K.25.E / 49
Bottom shaft - Install (K.25.E.56 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the bottom shaft in the straw elevator frame

and insert the shaft into the hole of the left-hand
side support (1).
IMPORTANT: Check if the bottom shaft is installed in the
right position. The flanges on the outer wheels are to the
left, and the flanges on the inner wheels are to the right.
ZDA6627A 1
2. Install the support (7) at the right-hand side and

insert the bottom shaft into the hole of the support
(7).
Install the bolt, the bushing and tighten the nut (6).
NOTE: Apply grease NLGI-2 onto the bushing before
installing.
ZDA5929D 2
3. Tighten the jam nut (5) with a minimum torque of

120 Nm. (88.5 lb ft)
4. Tighten the bolt (2) on both sides of the bottom shaft.
Tighten the nut (1) with a maximum torque of 28 Nm
(20.6 lb ft) on both sides.
ZDA6625A 3
12153 1 02/07/2004
K.25.E / 50
5. Connect the joining links on the chain and install

the coupler links (2).
Insert the cotter pins in the direction of travel and
bend the legs close to the pen.
ZDA6624A 4
6. At the right-hand side, install the bolt (4), the

bushing, the spring (3), the washer and the nut (2).
Adjust the both springs with the nuts (1) and (2) on
both sides.
NOTE: To adjust the height of the bottom shaft, refer to
the CS Operator’s manual: “SECTION 3 - FIELD AND
SITE OPERATION"; paragraph headed: “Lower shaft
adjustment".
ZDA5929E 5
7. Install the anti-dust plate (1).
ZDA6623A 6
12153 1 02/07/2004
K.25.E / 51
Intermediate plate - Remove (K.25.E.75 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Refer to Bottom shaft - Remove (K.25.E.56 -

F.10.A.10).
Remove the four bolts (1) on both sides of the
intermediate plate (2).
Slide the plate out of the frame.
ZDA6926A 1
12153 1 02/07/2004
K.25.E / 52
Intermediate plate - Install (K.25.E.75 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the intermediate plate in the straw elevator

frame.
Tighten the bolts.
NOTE: Before tighten the bolts, check if the intermediate
plate is in line with the fixed intermediate plate.
ZDA3463A 1
Next operation: Refer to Bottom shaft - Install (K.25.E.56 - F.10.A.15)
12153 1 02/07/2004
K.25.E / 53
Cradle - Remove (K.25.E.77 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Adjust the cradle in neutral position. This is

necessary to remove the axle through the hole (3).
Remove the cotter pin (1) to remove the axle (2).
ZDA7248A 1
2. To remove the axle to disconnect the hydraulic

cylinder from the cradle, push through the hole,
using a pin.
ZDA3549A 2
3. Remove the bolts (4).
ZDA7250A 3
12153 1 02/07/2004
K.25.E / 54
4. Remove the two bolts (5) on both sides of the cradle.

Loosen the two bolts (6), to remove the central axle.
ZDA7251A 4
5. To remove, hanging the cradle with ropes or a chain

and pull it upwards.
NOTE: The weight of the cradle is about 100 kg (220 lb).
ZDA7313A 5
6. Loosen the two bolts (5) to remove the shim pack

(6).
ZDA3417A 6
12153 1 02/07/2004
K.25.E / 55
Cradle - Install (K.25.E.77 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Grease the two bushings (1) with grease NLGI-2.
ZDA3457A 1
2. Install the two washers (8) with grease NLGI-2.
ZDA3418A 2
3. Bring the cradle on his place.

Install the central axle.
Tighten the two bolts (6).
Install the bolt (5) on both sides. Tighten the bolts
with a minimum torque of 164 Nm. (121 lb ft)
NOTE: Install the washer with the globular side against
the spacer.
NOTE: The spacer may never touch the slot.
ZDA7251A 3
12153 1 02/07/2004
K.25.E / 56
4. Adjust the plate (1) with the shim(s)(2) = 1 mm (3/64

in) until the clearance "X" = 0 mm between the
cradle and the face plate.
Turn the cradle at the left-hand side upwards and
grease the area (3) with grease NLGI-2.
Turn the cradle at the right-hand side upwards and
grease similar area.
Turn the cradle a few times with the hand up and
down.
Pry the cradle open against the face plate and add
an extra shim pack of 3 mm (1/8 in) on both sides.
(together with the shim (2))
Tighten the bolts with a minimum torque of 30
Nm.(22 lb ft.)
ZDA7324A 4
5. Install the axle (2) through the hole (3) to connect

the hydraulic cylinder of the cradle.
Grease the central axle.
ZDA7248A_128 5
6. Install the bolts (4) of the canvas.
ZDA7250A 6
12153 1 02/07/2004
K.25.E / 57
Cradle - Replace (K.25.E.77 - F.10.A.30)

CS540, CS640, CS520, CS660
Prior operation: Remove the cradle. Refer to Cradle - Remove (K.25.E.77 - F.10.A.10).
1. Clean the surfaces (1) of the cradle (2) with a

cleansing liquid. Refer to Cradle Seal - General
specification (K.25.E.77.40 - D.40.A.10)
Rub the surfaces (1) before gluing with a primer
for 10 minutes at 20 ° C.
ZDA7647A 1
2. Add the glue in the directions as shown onto the

common area and the chamfers of the seals.
NOTE: Check if the thickness of the glue painting is
between 0,5 - 2 mm.
ZDA7667A 2
3. Press the seals onto the cradle. Check if dimension

"X" is between 295 - 299 mm. (11-5/8 - 11-3/4 in)
4. To prevent damage, add the plates (3) onto the
seals (4).
Tighten the seals with the special tools (5) onto the
cradle for minimum 8 hours.
ZDA7648A 3
Next operation: Install the cradle. Refer to Cradle - Install (K.25.E.77 - F.10.A.15).
12153 1 02/07/2004
K.25.E / 58
Index
CROP PROCESSING - K
Bottom shaft - Assemble (K.25.E.56 - F.10.A.20) 48

CS540, CS640, CS520, CS660
Bottom shaft - Disassemble (K.25.E.56 - F.10.A.25) 47
CS540, CS640, CS520, CS660
Bottom shaft - Exploded view (K.25.E.56 - C.10.A.20) 11
CS540, CS640, CS520, CS660
Bottom shaft - Install (K.25.E.56 - F.10.A.15) 50
CS540, CS640, CS520, CS660
Bottom shaft - Remove (K.25.E.56 - F.10.A.10) 45
CS540, CS640, CS520, CS660
Cradle - Exploded view (K.25.E.77 - C.10.A.20) 12
CS540, CS640, CS520, CS660
Cradle - Install (K.25.E.77 - F.10.A.15) 56
CS540, CS640, CS520, CS660
Cradle - Remove (K.25.E.77 - F.10.A.10) 54
CS540, CS640, CS520, CS660
Cradle - Replace (K.25.E.77 - F.10.A.30) 58
CS540, CS640, CS520, CS660
Cradle Seal - General specification (K.25.E.77.40 - D.40.A.10) 6
CS540, CS640, CS520, CS660
CS540, CS520
CS640, CS660
Drive shaft - Exploded view (K.25.E.41 - C.10.A.20) 9
CS540, CS640, CS520, CS660
Drive shaft - Install (K.25.E.41 - F.10.A.15) 35
CS540, CS640, CS520, CS660
Drive shaft - Remove (K.25.E.41 - F.10.A.10) 32
CS540, CS640, CS520, CS660
Drive system Belt - Install (K.25.E.40.44 - F.10.A.15) 22
CS540, CS640, CS520, CS660
Drive system Belt - Remove (K.25.E.40.44 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Drive system Slip clutch - Assemble (K.25.E.40.46 - F.10.A.20) 29
CS540, CS640, CS520, CS660
Drive system Slip clutch - Disassemble (K.25.E.40.46 - F.10.A.25) 26
CS540, CS640, CS520, CS660
Drive system Slip clutch - Exploded view (K.25.E.40.46 - C.10.A.20) 8
CS540, CS640, CS520, CS660
Feed chain - Install (K.25.E.48 - F.10.A.15) 44
CS540, CS640, CS520, CS660
Feed chain - Remove (K.25.E.48 - F.10.A.10) 43
CS540, CS640, CS520, CS660
Intermediate plate - Install (K.25.E.75 - F.10.A.15) 53
CS540, CS640, CS520, CS660
12153 1 02/07/2004
K.25.E / 59
Intermediate plate - Remove (K.25.E.75 - F.10.A.10) 52
CS540, CS640, CS520, CS660
Pneumatic cylinder - Assemble (K.25.E.27 - F.10.A.20) 16
CS540, CS640, CS520, CS660
Pneumatic cylinder - Disassemble (K.25.E.27 - F.10.A.25) 13
CS540, CS640, CS520, CS660
Pneumatic cylinder - Sectional view (K.25.E.27 - C.10.A.30) 7
CS540, CS640, CS520, CS660
Reversing system - Exploded view (K.25.E.42 - C.10.A.20) 10
CS540, CS640, CS520, CS660
Reversing system Hydraulic motor - Install (K.25.E.42.28 - F.10.A.15) 40
CS540, CS640, CS520, CS660
Reversing system Hydraulic motor - Remove (K.25.E.42.28 - F.10.A.10) 37
CS540, CS640, CS520, CS660
12153 1 02/07/2004
K.25.E / 60
CROP PROCESSING - K
FEEDING Reel feeding - 25.B
CS540
CS640
CS520
CS660
12154 1 02/07/2004
K.25.B / 1
Contents
CROP PROCESSING - K
DIAGNOSTIC
Command
Command - Short circuit to ground (K.25.B.05 - G.30.B.53) 3
CS540, CS640, CS520, CS660
Speed regulation system

Speed regulation system - Open circuit (K.25.B.42 - G.30.B.50) 8
CS540, CS640, CS520, CS660
Sensing system
Sensing system Speed sensor - Short circuit to ground (K.25.B.95.80 - G.30.B.53) 13
CS540, CS640, CS520, CS660
Sensing system Speed sensor - Short circuit to B+ (K.25.B.95.80 - G.30.B.54) 20
CS540, CS640, CS520, CS660
Sensing system Speed sensor - Open circuit (K.25.B.95.80 - G.30.B.50) 27
CS540, CS640, CS520, CS660
Sensing system - Short circuit to ground (K.25.B.95 - G.30.B.53) 34
CS540, CS640, CS520, CS660
12154 1 02/07/2004
K.25.B / 2
CROP PROCESSING - FEEDING Reel feeding
Command - Short circuit to ground (K.25.B.05 - G.30.B.53)

CS540, CS640, CS520, CS660
E613 - REEL SPEED UP (FAST) SWITCH (S21) SHORT TO GROUND OR SHORT TO +VE
operation.
Context:
A short to ground on circuit (071) would blow the fuse F27 when the reel speed up switch is used.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty reel speed switch
Solution:

A. Disconnect the CCM connector X141. Turn the key start ON. Measure the voltage between connector

A. Turn the keystart OFF. Disconnect the multifunction handle connector X123. Turn the key start ON.
B. If the harness is okay, remove and replace the reel speed switch.
A. Turn the key start OFF. Check between connector X141 pin 22, circuit (071) (WT) and ground. If a short
the CCM.

(A.30.A - C.20.E.10)
CS540 1260 > 1324
CS640 1260 > 1324
12154 1 02/07/2004
K.25.B / 3

A8. CCM - reel 2730
X19. Header 2820
Line: 2720 - 2880
12154 1 02/07/2004
K.25.B / 4
vfil04cs0018h0a 1
12154 1 02/07/2004
K.25.B / 5

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

A8. CCM - reel 2730
X19. Header 2820
Line: 2720 - 2880
12154 1 02/07/2004
K.25.B / 6
vfil04cs0019h0a 2
12154 1 02/07/2004
K.25.B / 7
Speed regulation system - Open circuit (K.25.B.42 - G.30.B.50)

CS540, CS640, CS520, CS660
E612 - REEL VARIATOR (M5) OUTPUT OPEN OR SHORT CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty reel speed/brushes relays
4. Faulty reel speed relays
Solution:
1. Check the reel speed/brushes relays (slow/fast) connector K53 and K53.1, reel speed relays (slow/fast) K11
and K12, CCM connector X142, and the in-line harness connectors X122, X160, and X194.

A. Disconnect the CCM connector X142. Turn the key start ON. Measure the voltage between connector:
X142 pin 6, circuit (304) (GR) and ground
If a voltage is indicated, repair or replace the harness as required.

A. Disconnect the reel speed relay (slow) K11 and the reel speed relay (fast) K12. Check between
connector:
K12 pin 2, and ground
K11 pin 1, and ground

4. Connect the reel speed relay (slow) K11 and the reel speed relay (fast) K12. Check for short to ground.
A. Turn the key start OFF. Check between connector:

If a short to ground is indicated, continue to step 5.

connector:
12154 1 02/07/2004
K.25.B / 8
B. If a short to ground is not indicated, remove and replace the faulty reel speed relay.
connector:
X142 pin 6, circuit (304) (GR) and connector K12 pin 1, circuit (600) (GR)
X142 pin 8, circuit (305) (WT) and connector K11 pin 2, circuit (043) (WT)
the CCM.

(A.30.A - C.20.E.10)
CS540 1260 > 1324
CS640 1260 > 1324

A8. CCM - reel 2730
X19. Header 2820
12154 1 02/07/2004
K.25.B / 9

Line: 2720 - 2880
vfil04cs0018h0a 1
12154 1 02/07/2004
K.25.B / 10

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

A8. CCM - reel 2730
X19. Header 2820
Line: 2720 - 2880
12154 1 02/07/2004
K.25.B / 11
vfil04cs0019h0a 2
12154 1 02/07/2004
K.25.B / 12
Sensing system Speed sensor - Short circuit to ground

(K.25.B.95.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E125 - REEL SPEED (B27) SENSOR SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty reel speed sensor
Solution:
1. Check the reel speed sensor connector X147, CCM connector X141, and the in-line harness connectors X19
and X159.

(ZW) and ground. If a short to ground is indicated, remove and replace the reel speed sensor.


4. Check the reel speed sensor.
A. Connect connector X141. Remove the reel speed sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect reel speed sensor to connector X32. Turn the key start ON. Check if
the error code E119 is now also displayed. If error code E119 is displayed, replace the reel speed sensor.

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12154 1 02/07/2004
K.25.B / 13

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 14
55_a3cs016 1
12154 1 02/07/2004
K.25.B / 15

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 16
vfil04cs0026h0a 2
12154 1 02/07/2004
K.25.B / 17

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 18
vfil04cs0027h0a 3
12154 1 02/07/2004
K.25.B / 19
Sensing system Speed sensor - Short circuit to B+ (K.25.B.95.80 -

G.30.B.54)
CS540, CS640, CS520, CS660
E126 - REEL SPEED (B27) SENSOR SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the reel speed sensor connector X147 and the in-line harness connectors X19 and X159.


(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12154 1 02/07/2004
K.25.B / 20

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 21
55_a3cs016 1
12154 1 02/07/2004
K.25.B / 22

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 23
vfil04cs0026h0a 2
12154 1 02/07/2004
K.25.B / 24

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 25
vfil04cs0027h0a 3
12154 1 02/07/2004
K.25.B / 26
Sensing system Speed sensor - Open circuit (K.25.B.95.80 -

G.30.B.50)
CS540, CS640, CS520, CS660
E127 - REEL SPEED (B27) SENSOR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty reel speed sensor
Solution:
1. Check the reel speed sensor connector X147, CCM connector X141, and the in-line harness connectors X19
and X159.

A. Disconnect connect X147. Check between connector X147 pin 1, circuit (112) (ZW) and ground. If an

A. Turn the key start ON. Check between connector X147 pin 2, circuit (420) (GE) and ground. If the
voltage indicated is approximately +8 Volts, continue to step 4.

A. Turn the key start OFF. Remove the reel speed sensor. Disconnect the rotary separator sensor connector
X32. Connect the suspect reel speed sensor to connector X32. Turn the key start ON. Check if the error
code E121 is now also displayed. If error code E121 is displayed, replace the reel speed sensor.
the CCM.
12154 1 02/07/2004
K.25.B / 27

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 28
55_a3cs016 1
12154 1 02/07/2004
K.25.B / 29

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 30
vfil04cs0026h0a 2
12154 1 02/07/2004
K.25.B / 31

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12154 1 02/07/2004
K.25.B / 32
vfil04cs0027h0a 3
12154 1 02/07/2004
K.25.B / 33
Sensing system - Short circuit to ground (K.25.B.95 - G.30.B.53)

CS540, CS640, CS520, CS660
E614 - REEL SPEED DOWN (SLOW) SWITCH (S20) SHORT TO GROUND OR SHORT TO +VE
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty reel speed switch
Solution:

A. Disconnect the CCM connector X141. Turn the key start ON. Measure the voltage between connector

A. Turn the key start OFF. Disconnect the multifunction handle connector X123. Turn the key start ON.
Measure the voltage between connector X141 pin 23, circuit (070) (GR) and ground. If a voltage is
B. If the harness is okay, remove and replace the reel speed switch.
A. Turn the key start OFF. Check between connector X141 pin 23, circuit (070) (GR) and ground. If a short
the CCM.

(A.30.A - C.20.E.10)
CS540 1260 > 1324
CS640 1260 > 1324
12154 1 02/07/2004
K.25.B / 34

A8. CCM - reel 2730
X19. Header 2820
Line: 2720 - 2880
12154 1 02/07/2004
K.25.B / 35
vfil04cs0018h0a 1
12154 1 02/07/2004
K.25.B / 36

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

A8. CCM - reel 2730
X19. Header 2820
Line: 2720 - 2880
12154 1 02/07/2004
K.25.B / 37
vfil04cs0019h0a 2
12154 1 02/07/2004
K.25.B / 38
Index
CROP PROCESSING - K
Command - Short circuit to ground (K.25.B.05 - G.30.B.53) 3

CS540, CS640, CS520, CS660
Sensing system - Short circuit to ground (K.25.B.95 - G.30.B.53) 34
CS540, CS640, CS520, CS660
Sensing system Speed sensor - Open circuit (K.25.B.95.80 - G.30.B.50) 27
CS540, CS640, CS520, CS660
Sensing system Speed sensor - Short circuit to B+ (K.25.B.95.80 - G.30.B.54) 20
CS540, CS640, CS520, CS660
Sensing system Speed sensor - Short circuit to ground (K.25.B.95.80 - G.30.B.53) 13
CS540, CS640, CS520, CS660
Speed regulation system - Open circuit (K.25.B.42 - G.30.B.50) 8
CS540, CS640, CS520, CS660
12154 1 02/07/2004
K.25.B / 39
12154 1 02/07/2004
K.25.B / 40
CROP PROCESSING - K
THRESHING Conventional threshing - 40.B
CS540
CS640
CS520
CS660
12155 1 02/07/2004
K.40.B / 1
Contents
CROP PROCESSING - K
TECHNICAL DATA
Concave
Concave - General specification (K.40.B.58 - D.40.A.10) 4
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
THRESHING Conventional threshing - Logical diagram (K.40.B - C.20.B.72) 5

CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
THRESHING Conventional threshing - Overview (K.40.B - C.10.A.10) 9
CS540, CS640, CS520, CS660
Drum variator
Drum variator Drive disc - Sectional view (K.40.B.43.50 - C.10.A.30) 10
CS540, CS640, CS520, CS660
Drum variator Driven disc - Exploded view (K.40.B.43.51 - C.10.A.20) 11
CS540, CS640, CS520, CS660
Drum variator Driven disc - Sectional view (K.40.B.43.51 - C.10.A.30) 12
CS540, CS640, CS520, CS660
Drum
Drum - Exploded view (K.40.B.52 - C.10.A.20) 13
CS540, CS640, CS520, CS660
SERVICE
Speed regulation system

Speed regulation system - Adjust (K.40.B.42 - F.45.A.01) 14
CS540, CS640, CS520, CS660
Drum variator
Drum variator Belt - Remove (K.40.B.43.44 - F.10.A.10) 16
CS540, CS640, CS520, CS660
Drum variator Belt - Install (K.40.B.43.44 - F.10.A.15) 18
CS540, CS640, CS520, CS660
Drum variator Drive disc - Remove (K.40.B.43.50 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Drum variator Drive disc - Install (K.40.B.43.50 - F.10.A.15) 21
CS540, CS640, CS520, CS660
Drum variator Driven disc - Remove (K.40.B.43.51 - F.10.A.10) 23
CS540, CS640, CS520, CS660
12155 1 02/07/2004
K.40.B / 2
Drum variator Driven disc - Install (K.40.B.43.51 - F.10.A.15) 24
CS540, CS640, CS520, CS660
Drum
Drum Right hand bearing - Remove (K.40.B.52.01 - F.10.A.10) 25
CS540, CS640, CS520, CS660
Drum Right hand bearing - Install (K.40.B.52.01 - F.10.A.15) 27
CS540, CS640, CS520, CS660
Drum Left hand bearing - Remove (K.40.B.52.02 - F.10.A.10) 28
CS540, CS640, CS520, CS660
Drum Left hand bearing - Install (K.40.B.52.02 - F.10.A.15) 30
CS540, CS640, CS520, CS660
Drum - Remove (K.40.B.52 - F.10.A.10) 32
CS540, CS640, CS520, CS660
Drum - Install (K.40.B.52 - F.10.A.15) 35
CS540, CS640, CS520, CS660
Drum Rasp bar - Replace (K.40.B.52.03 - F.10.A.30) 37
CS540, CS640, CS520, CS660
Concave
Concave Pivot plate - Adjust (K.40.B.58.70 - F.45.A.01) 38
CS540, CS640, CS520, CS660
Anti-wrap shield
Anti-wrap shield - Adjust (K.40.B.72 - F.45.A.01) 40
CS540, CS640, CS520, CS660
DIAGNOSTIC
Sensing system
Sensing system Drum speed sensor - Short circuit to ground (K.40.B.95.80 - G.30.B.53) 41
CS540, CS640, CS520, CS660
Sensing system Drum speed sensor - Short circuit to B+ (K.40.B.95.80 - G.30.B.54) 48
CS540, CS640, CS520, CS660
Sensing system Drum speed sensor - Open circuit (K.40.B.95.80 - G.30.B.50) 55
CS540, CS640, CS520, CS660
12155 1 02/07/2004
K.40.B / 3
CROP PROCESSING - THRESHING Conventional threshing
Concave - General specification (K.40.B.58 - D.40.A.10)

CS540, CS640, CS520, CS660
TYPES OF DRUM CONCAVES
• Cereal concave:
Used for harvesting cereals, peas, ....)
• Maize concave:
Used for harvesting maize or beans.
• Rice concave:
Used for harvesting rice only.Distance of peg teeth on tooth bar: 56 mm (2-13/64 in)
CONCAVE SPECIFICATIONS
ZDA4404A 1
Concave type Wire distance A Wire distance B Wire diameter C Number of bars
Cereal concave 14 mm (9/16 in) 10 mm (3/8 in) 3.5 mm (9/64 in) 14
Maize concave 26 mm (1-3/128 in) 10 mm (3/8 in) 6 mm (1/4 in) 9
Rice concave 5 straw walkers 6 straw walkers

Distance of peg teeth 56 mm (2-13/64 in) 56 mm (2-13/64 in)
Number of peg tooth 4
bars
Number of peg teeth:
- 1 st bar (*) 13 (23) 14 (27)
- 2 nd bar (*) 13 (23) 16 (28)
- 3 rd bar 23 27
- 4 th bar 23 28
(*): The number of peg teeth on the table are installed on the concave. The other are delivered with a kit.
12155 1 02/07/2004
K.40.B / 4
THRESHING Conventional threshing - Logical diagram (K.40.B -

C.20.B.72)
CS540, CS640, CS520, CS660
07_23_36_05 1
THRESHING AND ROAD MODE ENGAGEMENT PROTECTION
12155 1 02/07/2004
K.40.B / 5
THRESHING AND ROAD MODE ENGAGEMENT PROTECTION FIGURE KEY

H5 UNLOADING TUBE OPEN/CLOSE LED
K45 UNLOADING TUBE PROTECTION RELAY
S32 UNLOADING TUBE PROTECTION SWITCH
S33 UNLOADING TUBE ENGAGEMENT SWITCH
Y8 UNLOADING ENGAGEMENT SOLENOID
Initial conditions:
A: Threshing mode must be selected and the threshing mechanism engaged.
B: Road mode must be selected.
A: Engagement protection if the unloading tube opens in threshing mode
When the initial conditions (A) are met, the unloading tube protection switch (S32) is open (the unloading tube is
retracted) and the unloading tube engagement switch (S33) is closed. The unloading tube protection relays (K47
and K45) are activated and the unloading tube protection relay (K46) is deactivated (unable to unload). The
unloading tube engagement solenoid (Y8) is deactivated (not unloading). When the unloading tube is extended, the
unloading tube protection switch (S32) becomes closed, which activates the unloading tube open/close LED (H5).
K46 is still deactivated meaning the unloading mechanism engagement solenoid (Y8) is still deactivated.
When the unloading tube engagement switch (S33) is open, the unloading tube protection relays (K47 and K45)
are deactivated, allowing a ground supply for the unloading tube protection relay (K46) to be activated. When the
unloading tube engagement switch (S33) is closed again, the unloading tube protection relay (K47) is activated and
the unloading tube protection relay (K45) remains deactivated. Power can now be supplied to the unloading tube
engagement solenoid (Y8) which activates the unloading auger.
B: Engagement protection if switched over from road mode to threshing mode
When the initial conditions (B) are met, the unloading tube protection switch (S32) is closed (the unloading tube is
extended) and the unloading tube engagement switch (S33) is closed. The unloading tube protection relays (K47,
K45 and K46) are deactivated (unable to unload). The unloading tube engagement solenoid (Y8) is deactivated (not
unloading). If threshing mode is selected at this point, power is supplied to the protection relays (K47 and K45), but
the unloading tube engagement solenoid (Y8) would remain deactivated.
When the unloading tube engagement switch (S33) is open, the unloading tube protection relays (K47 and K45) are
deactivated and the unloading tube protection relay (K46) is activated. When the unloading tube engagement switch
(S33) is closed again, the unloading tube protection relay (K47) is activated and the unloading tube protection relay
(K45) remains deactivated. Power can now be supplied to the unloading tube engagement solenoid (Y8) which
activates the unloading auger.
12155 1 02/07/2004
K.40.B / 6
THRESHING Conventional threshing - Logical diagram (K.40.B -

C.20.B.72)
CS540, CS640, CS520, CS660
07_23_36_07 1
THRESHING MECHANISM ENGAGEMENT
12155 1 02/07/2004
K.40.B / 7
THRESHING MECHANISM ENGAGEMENT FIGURE KEY

H21 PNEUMATIC PRESSURE (OK) CONTROL LIGHT (GREEN)
H22 PNEUMATIC PRESSURE (LOW) CONTROL LIGHT (RED)
K9 THRESHING ENGAGEMENT RELAY
K9.1 THRESHING ENGAGEMENT PROTECTION RELAY
K9.2 THRESHING ENGAGEMENT PROTECTION RELAY
K41 PNEUMATIC PRESSURE (THRESHING MECHANISM) RELAY
K42 PNEUMATIC PRESSURE (THRESHING MECHANISM) RELAY
S15 THRESHING MECHANISM SWITCH
S31 SAFETY ON THE ROAD SWITCH
S72 PRESSURE SWITCH - THRESHING MECHANISM
Y8 THRESHING MECHANISM ENGAGEMENT SOLENOID
Initial conditions:
Road mode must be selected and the threshing mechanism not engaged.
Road Mode:
When the initial conditions are met, the threshing engagement protection relay (K9.2) is activated, but there is no
power supply to the threshing mechanism pressure switch (S72) and the threshing mechanism engagement
solenoid (Y15). When the threshing mechanism switch (S15) is activated, the threshing engagement relay (K9)
remains deactivated, the protection relay (K9.1) is activated which deactivates the protection relay (K9.2). The
threshing mechanism engagement solenoid (Y15) remains deactivated as there is still no power supply to the
threshing mechanism pressure switch (S72).
Threshing Mode:
When the safety on the road switch (S31) is activated (threshing mode), power is supplied to activate the threshing
engagement relay (K9). The threshing engagement protection relay (K9.1) remains activated due to the take-over
contact in the relay, and the threshing engagement solenoid (Y8) will still remain deactivated, with no power supply
to the threshing mechanism pressure switch (S72).
To engage the threshing mechanism, the threshing engagement protection relay (K9.1) must be deactivated by
deactivating the threshing mechanism switch (S15) and activating it again. Power will now be supplied to the
threshing mechanism pressure switch (S72).
Green LED (H21) Illuminated (pneumatic pressure ok)
If the threshing mechanism pressure switch (S72) is sensing (ok pressure), power is supplied to illuminate the green
LED (H21) and to the threshing mechanism engagement solenoid (Y15), engaging the threshing system.
Red LED (H22) Illuminated (pneumatic pressure low)
If the threshing mechanism pressure switch (S72) is sensing (low pressure), power is supplied to illuminate the red
LED (H22) and to the pneumatic pressure relays (K41 and K42). The threshing mechanism engaging solenoid will
still remain deactivated.
When the pneumatic pressure builds up, the threshing mechanism pressure switch (S72) changes from a low
pressure state to a high pressure state, illuminating both the green LED (H21) and the red LED (H22). The
pneumatic pressure relay (K41) remains activated while the pneumatic pressure relay (K42) deactivates. To engage
the threshing mechanism, the threshing mechanism switch (S15) must be deactivated then activated again, this
will deactivate the remaining pneumatic pressure relay (K42). The red LED (H22) will extinguish, the green LED
(H21) will remain illuminated and power will be supplied to the threshing mechanism engagement solenoid (Y15),
engaging the threshing system.
12155 1 02/07/2004
K.40.B / 8
THRESHING Conventional threshing - Overview (K.40.B - C.10.A.10)

CS540, CS640, CS520, CS660
ZDA7323A 1
1 Threshing drum 2 Drum concave

3 Beater 4 Beater concave or rake
5 Rotary separator (if installed) 6 Rotary separator concave (if installed)
7 Straw walkers (5 or 6)
12155 1 02/07/2004
K.40.B / 9
Drum variator Drive disc - Sectional view (K.40.B.43.50 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDA7255A 1
Drum variator drive disc
1 Pulley 2 Bolt
3 Nut 4 Washer
5 Outer variator sheave 6 Inner variator sheave
7 Bearing 8 Variator belt
12155 1 02/07/2004
K.40.B / 10
Drum variator Driven disc - Exploded view (K.40.B.43.51 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7254A 1
Drum variator driven disc
1 Central bolt 2 Washer

3 Pressure plate 4 Spring
5 Bolt 6 Outer sheave
7 Special washers 8 Clutch
9 Inner sheave 10 Bolt
11 Clutch 12 Cam
12155 1 02/07/2004
K.40.B / 11
Drum variator Driven disc - Sectional view (K.40.B.43.51 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDA7142A 1
Drum variator driven disc
1 Central bolt 2 Washer

3 Pressure plate 4 Spring
5 Clutch 6 Outer sheave
7 Inner sheave 8 Clutch
9 Key
12155 1 02/07/2004
K.40.B / 12
Drum - Exploded view (K.40.B.52 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7014A 1
Drum bearings
1 Drum shaft 2 Keys

3 Ring 4 Bearing housing
5 Retaining ring 6 Bolt
7 Pulley 8 Washer
9 Bolt 10 Ring
11 Bearing housing 12 Bearing
13 Retaining ring 14 Bolt
12155 1 02/07/2004
K.40.B / 13
Speed regulation system - Adjust (K.40.B.42 - F.45.A.01)

CS540, CS640, CS520, CS660
1. Start the engine, switch on the threshing mechanism

and set the drum speed to maximum with the drum
speed rocker switch (1) until the top of the variator
belt runs equal or 1 mm under the outside of the
variator sheave.
ZDA6362D 1
2. Switch off the threshing mechanism and stop the

engine.
CAUTION
stopped rotating
3. Block the stop bracket (2) with the two nuts (3) and
(4).
ZDA7330A 2
4. Restart the engine, switch on the threshing

mechanism and set the drum speed to minimum
with the drum speed rocker switch (1) until the
variator sheave stops moving.
5. Switch off the threshing mechanism and stop the
engine.
CAUTION
stopped rotating
12155 1 02/07/2004
K.40.B / 14
6. Adjust the nut (5) so that the play "X" between the
stop bracket (2) and the nut (5) is between 0.5 -
1.5 mm.
ZDA7485A 3
12155 1 02/07/2004
K.40.B / 15
Drum variator Belt - Remove (K.40.B.43.44 - F.10.A.10)

CS540, CS640, CS520, CS660

and set the drum speed to minimum.
2. Switch of the threshing mechanism.
3. Open the unloading tube halfway.
4. Stop the engine.
CAUTION
stopped rotating
5. Remove the straw elevator drive belt. Refer to Drive

system Belt - Remove (K.25.E.40.44 - F.10.A.10).
6. Loosen the central bolt (1) to release the spring (4)
of the driven disks.
ZDA7235A 1
7. Remove the bolt (1), the washer (2), the pressure

plate (3) and the spring (4) completely.
ZDA7238A 2
12155 1 02/07/2004
K.40.B / 16
8. Loosen the six bolts (5) of the drum driven disks.

Remove the outer sheave (6).
ZDA7239A 3
9. Now is it possible to remove the drum variator drive

belt.
ZDA7236A 4
12155 1 02/07/2004
K.40.B / 17
Drum variator Belt - Install (K.40.B.43.44 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the variator belt.
ZDA7236A_135 1
2. Install the outer sheave (6) with the six bolts (5).
ZDA7239A_136 2
3. Install the spring (4), the pressure plate (3), the

washer (2) and the central bolt (1).
Tighten the central bolt (1) completely.
NOTE: To settle the variator belt properly, turn the variator
sheaves by hand while tightening the central bolt (1).
ZDA7238A_137 3
4. Grease the posi-torque.
Next operation: Install the straw elevator drive belt. Refer to Drive system Belt - Install (K.25.E.40.44 - F.10.A.15).
(K.40.B.42 - F.45.A.01).
12155 1 02/07/2004
K.40.B / 18
Drum variator Drive disc - Remove (K.40.B.43.50 - F.10.A.10)

CS540, CS640, CS520, CS660

and set the drum speed to minimum.
2. Switch of the threshing mechanism.
3. Stop the engine.
4. Remove the straw elevator drive belt. Refer to Drive
system Belt - Remove (K.25.E.40.44 - F.10.A.10).
5. Release the tension of the spring (4) by loosening
the central bolt (1).
ZDA7235A_141 1
6. From series 1320: Remove the central nut (3) and

the washer (4) of the drum variator drive disks.
ZDA7486A 2
7. From series 1416: Remove the counter nut (5),

the nut (3) and the washer (4) of the drum variator
drive disks.
ZEIL04CS0092A0B 3
12155 1 02/07/2004
K.40.B / 19
8. Remove the outer sheave (1). Push the inner

sheave to the inside to separate both sheaves.
ZDA7487A 4
9. Put away the variator belt and remove the inner

sheave (2).
ZDA7243A 5
12155 1 02/07/2004
K.40.B / 20
Drum variator Drive disc - Install (K.40.B.43.50 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Apply molybdeen sulphate grease to the inside of

the inner variator sheave (2).
Install the inner sheave (2) on the intermediate shaft.
Install the variator belt.
ZDA7243A_142 1
2. Install the outer sheave (1).

Install the shaft of the inner sheave over the shaft of
the outer sheave.
Push the both sheaves to the end and check that
the bearing is connect properly in the bearing
housing. (Refer to Drum variator - Sectional view
(K.40.B.43 - C.10.A.30))
ZDA7487A 2
3. From series 1320 onwards: Install the washer (4)

and the central nut (3) and tighten it with a torque
between 150 - 200 Nm. (111 - 148 lb ft)
ZDA7486A_143 3
12155 1 02/07/2004
K.40.B / 21
4. From series 1416 onwards: Install the washer (4).

Tighten the nut (3) with a torque of 200 Nm (148
lb ft).
Hold the nut (3) while tighten the counter nut (5)
with a torque of 250 Nm (184 lb ft).
ZEIL04CS0092A0B 4
5. Tighten the central bolt (1) completely to adjust the

tension of the spring (4).
NOTE: To settle the variator belt properly, turn the variator
sheaves by hand while tightening the central bolt (1).
ZDA7235A 5
Next operation: Install the straw elevator drive belt. Refer to Drive system Belt - Install (K.25.E.40.44 - F.10.A.15).
(K.40.B.42 - F.45.A.01).
12155 1 02/07/2004
K.40.B / 22
Drum variator Driven disc - Remove (K.40.B.43.51 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Refer to Drum variator Belt - Remove (K.40.B.43.44 - F.10.A.10)
1. Remove the two special washers (5).

Remove by turning the clutch (6).
ZDA7237A 1
2. Loosen the six nuts (1).

Now is it possible to remove the inner sheave (2)
of the driven disks.
ZDA7240A 2
3. Remove the clutch (3).
ZDA7241A 3
12155 1 02/07/2004
K.40.B / 23
Drum variator Driven disc - Install (K.40.B.43.51 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the clutch (3) onto the beater shaft.
ZDA7241A_138 1
2. Install the inner sheave (2) and tighten it with the

six bolts (1).
ZDA7240A_139 2
3. Install the hub (6).

NOTE: Grease the inner side of the hub (6) with grease
molybdeen sulphate.
ZDA7237A_140 3
4. Install the two special washers (5).
Next operation: Refer to Drum variator Belt - Install (K.40.B.43.44 - F.10.A.15).

Next operation: Refer to Drive system Belt - Install (K.25.E.40.44 - F.10.A.15).
Next operation: Refer to Speed regulation system - Adjust (K.40.B.42 - F.45.A.01).
12155 1 02/07/2004
K.40.B / 24
Drum Right hand bearing - Remove (K.40.B.52.01 - F.10.A.10)

CS540, CS640, CS520, CS660

Operator’s Manual: SECTION 3 - “FIELD AND
SITE OPERATION", paragraph: "Straw elevator -
2. Support the drum.
3. Loosen the idler by turning the shaft (3) counter
clockwise, using a spanner of 19 mm. (3/4 in)
Remove the belt (5) from the pulley.
ZDA6440A 1
4. Remove the central bolt (1) and the washer (2).

Remove the pulley (3), using a puller.
ZDA7005A 2

Loosen the three bolts (5) of the bearing housing.
ZDA7006A 3
12155 1 02/07/2004
K.40.B / 25

housing, by using a puller.
ZDA7006B 4
12155 1 02/07/2004
K.40.B / 26
Drum Right hand bearing - Install (K.40.B.52.01 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the bearing (1) in the bearing housing (2) with

grease (NLGI-2) on the spherical outer ring.
Install the retaining ring (3) in the bearing housing.
Install the ring (4) on the shaft (5).
Install the bearing housing (2) onto the shaft (5) by
using a tube.
ZDA7007A 1
2. Install and tighten the bolts (5).

ZDA7006A_129 2

Install the washer (2) and tighten the central bolt (1).
ZDA7005A 3
4. Remove the support to unblock the drum.

5. Install the belt, (Refer to the Operator’s
Manual: SECTION 4 - “LUBRICATION AND
MAINTENANCE", paragraph: “Drive belts and
chains".
6. Attach the straw elevator. Refer to the CS
Operator’s Manual: SECTION 3 - “FIELD AND SITE
OPERATION", paragraph headed: “Straw elevator -
12155 1 02/07/2004
K.40.B / 27
Drum Left hand bearing - Remove (K.40.B.52.02 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Detach the straw elevator. Refer to the Operator’s

Manual: SECTION 3 - “FIELD AND SITE
OPERATION", paragraph: "Straw elevator -
2. Release the tension of the drum drive belt (5) by
turning the shaft (3) counter clockwise, using a
spanner of 19 mm. (3/4 in)
Support the drum.
ZDA6440A_131 1
3. Remove the nut (1) of the pneumatic cylinder.
ZDA7008A 2
4. Loosen the two bolts (2) to remove the sensor

support.
Loosen the central bolt (3) to remove the speed
indicator plate (4).
ZDA7009A 3
12155 1 02/07/2004
K.40.B / 28
5. Loosen the three bolts (5) of the bearing housing.

Remove the bearing housing (6) by using a puller.
ZDA7010A 4
6. Remove the ring (7), if necessary.
ZDA7011A 5
12155 1 02/07/2004
K.40.B / 29
Drum Left hand bearing - Install (K.40.B.52.02 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the bearing (1) in the bearing housing (2) with

grease NLGI-2 on the spherical outer ring. Apply
anti-corrosive grease to the inner ring of the bearing.
Install the retaining ring (3) in the bearing housing.
Install the ring (4) onto the shaft.
ZDA7012A 1
2. Install the bearing housing (2) onto the shaft, using

a tube.
ZDA7013A 2
3. Install and tighten the three bolts (5).

Apply anti-corrosive protector to the shaft end.
ZDA7010A 3
12155 1 02/07/2004
K.40.B / 30
4. Install the speed indicator plate (4) and tighten it

with the central bolt (3).
Install the sensor support and tighten the bolts (2).
Adjust the sensor if necessary.
ZDA7009A_132 4

At the right-hand side, tighten the belt (5) by turning
the shaft (3) clockwise.
ZDA6440A 5
6. Attach the straw elevator. Refer to the CS

Operator’s Manual: SECTION 3 - “FIELD AND SITE
OPERATION", paragraph headed: "Straw elevator -
12155 1 02/07/2004
K.40.B / 31
Drum - Remove (K.40.B.52 - F.10.A.10)

CS540, CS640, CS520, CS660

2. Open the stone trap and the pivot plate.
3. Remove the drum concave. Refer to the CS
SITE OPERATION", paragraph: "Drum concave -
4. Remove the anti-dust plate (1) completely.
Remove the anti-wrap shields (2) on both sides.
ZDA6157D 1
5. Loosen the bolts (4) of the drum discs.
ZDA7307A 2
6. Support the drum on both sides and remove the

left-hand side bearing of the drum. Refer to Drum
Left hand bearing - Remove (K.40.B.52.02 -
F.10.A.10) .
ZDA7310A 3
12155 1 02/07/2004
K.40.B / 32
7. Remove the five bolts (1), (2), (3),(4) and (5) (fig.5)
on both sides to remove the support (6) on both
sides.
ZDA7308A 4
8.
ZDA7309A 5
9. At the right-hand side, loosen the central bolt (1)

and remove the washer (2).
ZDA7005A 6

Loosen the three bolts (5) of the bearing housing
and slide the drum shaft and the bearing housing
out to the right.
ZDA7006A 7
12155 1 02/07/2004
K.40.B / 33
11. Remove the drum out of the combine.

NOTE: Be careful to lift the drum, because the drum is
heavy.
ZDA7319A 8
12155 1 02/07/2004
K.40.B / 34
Drum - Install (K.40.B.52 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the drum into the combine, using an adequate

lifting device.
ZDA7319A_133 1
2. Bring the shaft in the drum from the right-hand side

and install the bearing housing with the three bolts
(5) on this side.
ZDA7006A 2
3. Install the left-hand side bearing. Drum Left hand

bearing - Install (K.40.B.52.02 - F.10.A.15).
5. Adjust the drum in the middle of the frame (the
maximum difference in clearance left-hand side
relative to right-hand side = 3 mm (1/8 in) to be
measured on the nearest slat and at the nearest
spot and blocked with the bolts (4) of the drum
discs. Tighten the bolts (4) to a standard torque.
ZDA7307A 3
12155 1 02/07/2004
K.40.B / 35
6. At the right-hand side, install the pulley (3), the

washer (2) and tighten the central bolt (1).
ZDA7005A 4
7. Install the drum drive belt (5) and turn the shaft (3)
clockwise.
NOTE: If necessary, adjust the belt tension as described
in the CS Operator’s Manual: SECTION 4- LUBRICATION
AND MAINTENANCE: paragraph headed: “Drive belts
and chains".
ZDA6440A 5
8. Install the supports (6) on both sides and tighten the

bolts (1), (2), (3), (4) and (5).
ZDA7309A 6
9. Install the anti-wrap shields (2) and the anti-dust

plate (1).
Attach the straw elevator. Refer to the CS
ZDA6157D 7
12155 1 02/07/2004
K.40.B / 36
Drum Rasp bar - Replace (K.40.B.52.03 - F.10.A.30)

CS540, CS640, CS520, CS660
Always replace the rasp bars in pairs (as they are delivered), each bar located 180 degrees apart from the other.
The maximum weight difference allowed between the bars of one set is 25 gram. (0.06 lb ft)
IMPORTANT: Use always new bolts when replacing the rasp bars.
1. Tighten the nuts to a minimum torque of 100 Nm.
(73.8 lb ft)
NOTE: The drum discs are marked with a punch. When
installing the drum, all marks should be aligned. In this
position the drum was balanced.
12155 1 02/07/2004
K.40.B / 37
Concave Pivot plate - Adjust (K.40.B.58.70 - F.45.A.01)

CS540, CS640, CS520, CS660
After installation of the concave, it is necessary to adjust the plate (1) of the pivot plate.
1. Place the concave in the highest position.
ZDA6972A 1
2. Open the pivot plate (2) (slide the left and the
right-hand side levers (3) towards the centre of the
stone trap).
ZDA7023A 2
3. Loosen the bolts (4) to adjust the plate.
ZDA6977A 3
12155 1 02/07/2004
K.40.B / 38
4. Adjust the plate (1) until the distance "X" = between

1 - 4 mm. (5/128 - 5/32 in)
ZDA6978A 4
5. Tighten the bolts (4).
ZDA6977A_134 5
12155 1 02/07/2004
K.40.B / 39
Anti-wrap shield - Adjust (K.40.B.72 - F.45.A.01)

CS540, CS640, CS520, CS660
1. In case of a cereal concave, the anti-wrap shields

(1) has to be installed on both sides of the drum with
dimension “X" between 2 - 5 mm, measured with
regard to the rasp bar with on the largest radius.
ZDA7327A 1
2. To adjust the anti-wrap shields (1), loosen the two

bolts (2) on both sides of the drum.
After adjusting, tighten the bolts (2).
ZDA7328A 2
12155 1 02/07/2004
K.40.B / 40
Sensing system Drum speed sensor - Short circuit to ground

(K.40.B.95.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E104 - DRUMSPEED SENSOR (B9) SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty drum speed sensor
Solution:
1. Check the drum speed sensor connector X29, CCM connector X142, and the in-line harness connector X26.

(ZW) and ground. If a short to ground is indicated, remove and replace the drum speed sensor.


4. Check the drum speed sensor.
A. Connect connector X142. Remove the drum speed sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect drum speed sensor to connector X32. Turn the key start ON.
Check if the error code E119 is now also displayed. If error code E119 is displayed, replace the drum
speed sensor.

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12155 1 02/07/2004
K.40.B / 41

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 42
55_a3cs016 1
12155 1 02/07/2004
K.40.B / 43

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 44
vfil04cs0026h0a 2
12155 1 02/07/2004
K.40.B / 45

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 46
vfil04cs0027h0a 3
12155 1 02/07/2004
K.40.B / 47
Sensing system Drum speed sensor - Short circuit to B+

(K.40.B.95.80 - G.30.B.54)
CS540, CS640, CS520, CS660
E105 - DRUMSPEED SENSOR (B9) SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the drum speed sensor connector X29 and the in-line harness connector X26.


(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12155 1 02/07/2004
K.40.B / 48

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 49
55_a3cs016 1
12155 1 02/07/2004
K.40.B / 50

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 51
vfil04cs0026h0a 2
12155 1 02/07/2004
K.40.B / 52

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 53
vfil04cs0027h0a 3
12155 1 02/07/2004
K.40.B / 54
Sensing system Drum speed sensor - Open circuit (K.40.B.95.80 -

G.30.B.50)
CS540, CS640, CS520, CS660
E106 - DRUMSPEED SENSOR (B9) OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty drum speed sensor
Solution:
1. Check the drum speed sensor connector X29, CCM connector X142, and the in-line harness connector X26.



A. Turn the key start OFF. Remove the drum speed sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect drum speed sensor to connector X32. Turn the key start ON.
Check if the error code E121 is now also displayed. If error code E121 is displayed, replace the drum
speed sensor.
the CCM.
12155 1 02/07/2004
K.40.B / 55

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 56
55_a3cs016 1
12155 1 02/07/2004
K.40.B / 57

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 58
vfil04cs0026h0a 2
12155 1 02/07/2004
K.40.B / 59

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12155 1 02/07/2004
K.40.B / 60
vfil04cs0027h0a 3
12155 1 02/07/2004
K.40.B / 61
Index
CROP PROCESSING - K
Anti-wrap shield - Adjust (K.40.B.72 - F.45.A.01) 40

CS540, CS640, CS520, CS660
Concave - General specification (K.40.B.58 - D.40.A.10) 4
CS540, CS640, CS520, CS660
Concave Pivot plate - Adjust (K.40.B.58.70 - F.45.A.01) 38
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Drum - Install (K.40.B.52 - F.10.A.15) 35
CS540, CS640, CS520, CS660
Drum - Remove (K.40.B.52 - F.10.A.10) 32
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Drum Rasp bar - Replace (K.40.B.52.03 - F.10.A.30) 37
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Drum variator Belt - Install (K.40.B.43.44 - F.10.A.15) 18
CS540, CS640, CS520, CS660
Drum variator Belt - Remove (K.40.B.43.44 - F.10.A.10) 16
CS540, CS640, CS520, CS660
Drum variator Drive disc - Install (K.40.B.43.50 - F.10.A.15) 21
CS540, CS640, CS520, CS660
Drum variator Drive disc - Remove (K.40.B.43.50 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Drum variator Drive disc - Sectional view (K.40.B.43.50 - C.10.A.30) 10
CS540, CS640, CS520, CS660
Drum variator Driven disc - Exploded view (K.40.B.43.51 - C.10.A.20) 11
CS540, CS640, CS520, CS660
Drum variator Driven disc - Install (K.40.B.43.51 - F.10.A.15) 24
CS540, CS640, CS520, CS660
Drum variator Driven disc - Remove (K.40.B.43.51 - F.10.A.10) 23
CS540, CS640, CS520, CS660
Drum variator Driven disc - Sectional view (K.40.B.43.51 - C.10.A.30) 12
CS540, CS640, CS520, CS660
Sensing system Drum speed sensor - Open circuit (K.40.B.95.80 - G.30.B.50) 55
CS540, CS640, CS520, CS660
Sensing system Drum speed sensor - Short circuit to B+ (K.40.B.95.80 - G.30.B.54) 48
CS540, CS640, CS520, CS660
Sensing system Drum speed sensor - Short circuit to ground (K.40.B.95.80 - G.30.B.53) 41
CS540, CS640, CS520, CS660
12155 1 02/07/2004
K.40.B / 62
Speed regulation system - Adjust (K.40.B.42 - F.45.A.01) 14
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
THRESHING Conventional threshing - Overview (K.40.B - C.10.A.10) 9
CS540, CS640, CS520, CS660
12155 1 02/07/2004
K.40.B / 63
12155 1 02/07/2004
K.40.B / 64
CROP PROCESSING - K
SEPARATING Beating - 42.B
CS540
CS640
CS520
CS660
12156 1 02/07/2004
K.42.B / 1
Contents
CROP PROCESSING - K
FUNCTIONAL DATA
Drum
CS540, CS640, CS520, CS660
SERVICE
Drum
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Drum Shaft - Remove (K.42.B.52.40 - F.10.A.10) 11
CS540, CS640, CS520, CS660
Drum Shaft - Install (K.42.B.52.40 - F.10.A.15) 13
CS540, CS640, CS520, CS660
12156 1 02/07/2004
K.42.B / 2
CROP PROCESSING - SEPARATING Beating
Drum - Exploded view (K.42.B.52 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA7082A 1
Beater shaft + bearings
1 Shaft 2 Key
3 Ring 4 Bearing housing
5 Left-hand side bearing 6 Retaining ring
7 Bolt 8 Bearing housing
9 Right-hand side bearing 10 Ring
11 Ring 12 Retaining ring
13 Bolt 14 Idler
15 Bolt 16 Idler support
17 Washer 18 Retaining ring
19 Shims 20 Pulley
21 Washer 22 Central bolt
12156 1 02/07/2004
K.42.B / 3
Drum Right hand bearing - Remove (K.42.B.52.01 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Loosen the idler by turning the shaft (3) counter

clockwise, using a spanner of 19 mm. (3/4 in)
Remove the belt (5) completely.
ZDA6440A_145 1
2. Loosen the central bolt (1) and the washer.
ZDA7083A 2
3. Remove the pulley (2), using a puller.

Remove the key.
ZDA7253A 3
12156 1 02/07/2004
K.42.B / 4
4. Remove the bolt (4) to remove the idler (5).
ZDA7073A 4
5. Remove the retaining ring (6) and the washer.

Remove the two bolts (7). Now is it possible to
remove the idler support completely.
ZDA7074A 5
6. Support the beater.

Loosen the four bolts (1) of the bearing housing (2).
ZDA7075A 6
7. Install two threaded rods to pull of the bearing

housing, using a puller.
ZDA7076A 7
12156 1 02/07/2004
K.42.B / 5
Drum Right hand bearing - Install (K.42.B.52.01 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Grease the seals of the bearing (1) with grease

NLGI-2.
Install the bearing (1) in the bearing housing (2)
with multipurpose grease NLGI-2 on the spherical
outer ring.
Install the ring (3) and the retaining ring (4).
ZDA7078A 1
2. Press the ring (5) with the bearing housing (2) onto
the shaft with anti-corrosive grease on the inner ring
of the bearing (1). (fig.1)
ZDA7079A 2
3. Install and tighten the four bolts (1) of the bearing

housing (2).
ZDA7075A_146 3
12156 1 02/07/2004
K.42.B / 6
4. Install the idler support onto the bearing housing.

Install the washer and the retaining ring (6).
Install and tighten the two nuts (7).
ZDA7074A_147 4
5. Install the idler (5) and tighten the bolt (4).
ZDA7073A_148 5
6. Install the key (1) in the right position as shown.
ZDA7820A 6
7. Install the pulley (2). Check if the pulley is in

line with the pulley of the drum. If not add shims
between the pulley (2) and the ruff of the shaft.
ZDA7253A 7
12156 1 02/07/2004
K.42.B / 7
8. Install the washer and tighten the central bolt.
ZDA7083A_149 8
9. Install the belt and adjust as described in

the CS-Operator’s Manual; SECTION 4 -
“LUBRICATION AND MAINTENANCE", paragraph
“Drive belts and chains - Right-hand side".
12156 1 02/07/2004
K.42.B / 8
Drum Left hand bearing - Remove (K.42.B.52.02 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Refer to Drum variator Driven disc - Remove (K.40.B.43.51 - F.10.A.10)
1. Support the beater.

Loosen the three bolts (2).
ZDA7069A 1

housing (3), using a puller.
ZDA7070A 2
4. If necessary, remove the ring (4).
ZDA7072A 3
12156 1 02/07/2004
K.42.B / 9
Drum Left hand bearing - Install (K.42.B.52.02 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the bearing (6) in bearing housing (3) with

multipurpose grease NLGI-2 on the spherical outer
ring.
Grease the seals of the bearing with grease NLGI-2.
Install the ring (4) onto the beater shaft (5).
Press the bearing housing (3) onto the beater shaft.
ZDA7071A 1
2. Install and tighten three bolts (2).
ZDA7069A_144 2
3. Install the key (1).

IMPORTANT: Be sure that the key (1) is installed in the
right position as shown.
ZDA7820A 3
4. Remove the support to unblock the beater.
Next operation: Refer to Drum variator Driven disc - Install (K.40.B.43.51 - F.10.A.15).
12156 1 02/07/2004
K.42.B / 10
Drum Shaft - Remove (K.42.B.52.40 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Remove the right-hand side beater bearing, refer to Drum Right hand bearing - Remove
(K.42.B.52.01 - F.10.A.10)
Prior operation: At the left-hand side, remove the drum variator driven disks and the bearing, refer to Drum Left
hand bearing - Remove (K.42.B.52.02 - F.10.A.10)
1. Enter the grain tank and remove the cover to have

access to the beater.
ZDA7249A 1
2. Search the marker with sign “X" by turning the

beater manually.
Loosen the bolts (2) and remove the stripper plate
(1).
ZDA7080B 2
3. Loosen the four bolts (1).
ZDA7314A 3
12156 1 02/07/2004
K.42.B / 11
4. Support the beater and keep the keys on the top

side.
Slide the beater shaft (3) out to the left-hand side,
using a tube.
ZDA7081A 4
12156 1 02/07/2004
K.42.B / 12
Drum Shaft - Install (K.42.B.52.40 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Insert the beater shaft (3) with the keys installed

from the left-hand side.
ZDA7081A_150 1
2. Install the left-hand side bearing. Refer to Drum

Left hand bearing - Install (K.42.B.52.02 -
F.10.A.15).
3. Install the right-hand side bearing. Refer to Drum
Right hand bearing - Install (K.42.B.52.01 -
F.10.A.15).
4. Enter the grain tank and adjust the beater so that
dimension “X" at the left-hand side is between 16
- 20 mm. (5/8 - 3/4 in)
ZDA7331A 2
5. Tighten the four bolts (1) to the standard torque.
ZDA7314A 3
6. Install the beater stripper plate (or toothed bar).

To adjust the stripper plate, refer to the CS
Operator’s manual; “SECTION 3 - FIELD AND SITE
OPERATION", paragraph: “Separation", headed:
Adjustable stripper plates".
12156 1 02/07/2004
K.42.B / 13
7. Close the cover in the grain tank.
ZDA7249A 4
Next operation: Refer to Drum variator Driven disc - Install (K.40.B.43.51 - F.10.A.15)
12156 1 02/07/2004
K.42.B / 14
Index
CROP PROCESSING - K

CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Drum Shaft - Install (K.42.B.52.40 - F.10.A.15) 13
CS540, CS640, CS520, CS660
Drum Shaft - Remove (K.42.B.52.40 - F.10.A.10) 11
CS540, CS640, CS520, CS660
12156 1 02/07/2004
K.42.B / 15
12156 1 02/07/2004
K.42.B / 16
CROP PROCESSING - K
SEPARATING Rotary separator - 42.C
CS540
CS640
CS520
CS660
12157 1 02/07/2004
K.42.C / 1
Contents
CROP PROCESSING - K
FUNCTIONAL DATA
Drum
Drum - Exploded view (K.42.C.52 - C.10.A.20) 3
CS540, CS640, CS660
SERVICE
SEPARATING Rotary separator - Remove (K.42.C - F.10.A.10) 4

CS540, CS640, CS660
SEPARATING Rotary separator - Install (K.42.C - F.10.A.15) 5
CS540, CS640, CS660
Drive system
Drive system Belt - Remove (K.42.C.40.44 - F.10.A.10) 6
CS540, CS640, CS660
Drive system Belt - Install (K.42.C.40.44 - F.10.A.15) 7
CS540, CS640, CS660
Drum
Drum Right hand bearing - Remove (K.42.C.52.01 - F.10.A.10) 8
CS540, CS640, CS660
Drum Right hand bearing - Install (K.42.C.52.01 - F.10.A.15) 11
CS540, CS640, CS660
Drum Left hand bearing - Remove (K.42.C.52.02 - F.10.A.10) 14
CS540, CS640, CS660
Drum Left hand bearing - Install (K.42.C.52.02 - F.10.A.15) 16
CS540, CS640, CS660
Drum Shaft - Remove (K.42.C.52.40 - F.10.A.10) 18
CS540, CS640, CS660
Drum Shaft - Install (K.42.C.52.40 - F.10.A.15) 20
CS540, CS640, CS660
DIAGNOSTIC
Sensing system
Sensing system Speed sensor - Short circuit to ground (K.42.C.95.50 - G.30.B.53) 21
CS540, CS640, CS660
Sensing system Speed sensor - Short circuit to B+ (K.42.C.95.50 - G.30.B.54) 28
CS540, CS640, CS660
Sensing system Speed sensor - Open circuit (K.42.C.95.50 - G.30.B.50) 35
CS540, CS640, CS660
12157 1 02/07/2004
K.42.C / 2
CROP PROCESSING - SEPARATING Rotary separator
Drum - Exploded view (K.42.C.52 - C.10.A.20)

CS540, CS640, CS660
ZDA7033A 1
Rotary separator
1 Shaft 2 Key
3 Bearing (left-hand side) 4 Bearing (right-hand side)
5 Hub 6 Pulley
7 Idler 8 Central bolt
9 Rotary separator 10 Anti-wrap shield
11 Bolt 12 Counter nut
12157 1 02/07/2004
K.42.C / 3
SEPARATING Rotary separator - Remove (K.42.C - F.10.A.10)

CS540, CS640, CS660
Prior operation: Remove the straw walkers, refer to Straw walker - Remove (K.42.E.58 - F.10.A.10).
Prior operation: Remove the left-hand side rotary separator bearing. Refer to Drum Left hand bearing - Remove
(K.42.C.52.02 - F.10.A.10).
Prior operation: Remove the right-hand side rotary separator bearing. Refer to Drum Right hand bearing -
Remove (K.42.C.52.01 - F.10.A.10).
Prior operation: Remove the rotary separator shaft. Refer to Drum Shaft - Remove (K.42.C.52.40 - F.10.A.10).
1. Loosen the four bolts (1) of the anti-wrap shields

on both sides.
ZDA7031A 1
2. Take out of the rotary separator drum to the rear of

the combine, using an adequate lifting device. The
weight of the drum is about 110 kg (243 lb).
12157 1 02/07/2004
K.42.C / 4
SEPARATING Rotary separator - Install (K.42.C - F.10.A.15)

CS540, CS640, CS660
1. Bring the rotary separator with the anti-wrap shields

on his place, using an adequate lifting device.
2. Install the anti-wrap shields (2) with the opening to
the rear of the combine.
Tighten the four bolts (1) on both sides.
ZDA7034A 1
Next operation: Install the rotary separator shaft. Refer to Drum Shaft - Install (K.42.C.52.40 - F.10.A.15).
Next operation: Install the right-hand side rotary separator bearing. Refer to Drum Right hand bearing - Install
(K.42.C.52.01 - F.10.A.15).
Next operation: Install the left-hand side rotary separator bearing. Refer to Drum Left hand bearing - Install
(K.42.C.52.02 - F.10.A.15).
Next operation: Install the straw walkers, refer to Straw walker - Install (K.42.E.58 - F.10.A.15).
12157 1 02/07/2004
K.42.C / 5
Drive system Belt - Remove (K.42.C.40.44 - F.10.A.10)

CS540, CS640, CS660
Prior operation: Remove first the fan variator drive belt and the cleaning shoe drive belt. Refer to Shoe drive
system Belt - Remove (K.62.B.45.44 - F.10.A.10).
1. Release the rotary separator drive belt (2) by

moving the handle (1).
ZDA6261A 1
2. Now is it possible to remove the rotary separator

drive belt (2).
ZDA7265A 2
12157 1 02/07/2004
K.42.C / 6
Drive system Belt - Install (K.42.C.40.44 - F.10.A.15)

CS540, CS640, CS660
1. Install the rotary separator drive belt.
ZDA7265A 1
2. Install the cleaning shoe drive belt and the cleaning

fan drive belt. Refer to Shoe drive system Belt -
Install (K.62.B.45.44 - F.10.A.15) .
3. Tighten the belt (2) by moving the handle (1).
ZDA6261A 2
4. To adjust the belt tension, refer to the CS Operator’s

Manual; "SECTION 4 - LUBRICATION AND
MAINTENANCE"; paragraph headed: "Drive belts
and chains".
12157 1 02/07/2004
K.42.C / 7
Drum Right hand bearing - Remove (K.42.C.52.01 - F.10.A.10)

CS540, CS640, CS660
1. At the right-hand side, remove the cover (1).

Support the rotary separator.
ZDA7026A 1
2. Adjust the rotary separator concave in the lowest

position by moving the lever (1) completely upwards.
ZDA6261C 2
3. Release the rotary separator drive belt (2) by

moving the handle (1).
ZDA6261A 3
12157 1 02/07/2004
K.42.C / 8
4. Remove the bolt (2).

Remove the central bolt (3) and the washer.
ZDA7019A 4
5. Remove the idler support (4), using a puller.
ZDA7245A 5
6. Loosen the four bolts (5) to remove the pulley.
ZDA7028A 6
7. Remove the hub (6), using a puller.
ZDA7246A 7
12157 1 02/07/2004
K.42.C / 9

Loosen the Allen screw and remove the lock collar
(2).
ZDA7020A 8
9. Loosen the four bolts (3).

Remove the bearing (4), using a puller.
ZDA7021A 9
12157 1 02/07/2004
K.42.C / 10
Drum Right hand bearing - Install (K.42.C.52.01 - F.10.A.15)

CS540, CS640, CS660
1. Install the bearing (4) with grease "molybdeen

sulphate" on the inner ring to the rotary separator
shaft.
ZDA7021A_154 1
2. Install the lock collar (2) and tighten the Allen screw.
Install the hub (3).
Install the pulley (4) and tighten the four bolts.
NOTE: Don’t forget to install the belt first.
ZDA7022A 2
12157 1 02/07/2004
K.42.C / 11
3. Install the support of the idler (5). (See also fig.2)

NOTE: Put grease NLGI-2 on the seals of the bearings (6).
ZDA7027A 3
4. Install and tighten the central bolt (3) with a torque

between 40 - 50 Nm. (29 - 37 lb ft)
Install the bolt (2) to attach the idler with the lever.
ZDA7019A_155 4
5. Install the rotary separator drive belt (2) by using

the lever (1) and adjust if necessary as described
in the CS Operator’s Manual; SECTION 4 -
“LUBRICATION AND MAINTENANCE", paragraph
“Drive belts and chains - Right-hand side".
ZDA6261A_156 5
6. Remove the support to unblock the rotary separator.

7. Place the rotary separator concave in the closed
position, if necessary.
12157 1 02/07/2004
K.42.C / 12
8. Install the cover (1).
ZDA7026A 6
12157 1 02/07/2004
K.42.C / 13
Drum Left hand bearing - Remove (K.42.C.52.02 - F.10.A.10)

CS540, CS640, CS660
1. At the left-hand side, remove the cover (1).

Support the rotary separator.
ZDA7015A 1
2. Loosen the central bolt (2) and remove the speed

indicator plate (3).
ZDA7016A 2
3. Loosen the Allen screw to remove the lock collar (4).
ZDA7024A 3
12157 1 02/07/2004
K.42.C / 14
4. Loosen the three bolts (5) and remove the speed

sensor support (6).
Remove the bearing completely, using a puller.
ZDA7017A 4
12157 1 02/07/2004
K.42.C / 15
Drum Left hand bearing - Install (K.42.C.52.02 - F.10.A.15)

CS540, CS640, CS660
1. Install the bearing with grease "molybdeen sulphate"

on the inner ring to the rotary separator shaft.
Install and tighten the three bolts (5). Don’t forget to
install the speed sensor support (6).
ZDA7017A_151 1
2. Grease the lock collar with "molybdeen sulphate"

grease. Install the lock collar (4) and tighten the
Allen screw.
ZDA7018A 2
3. Install the speed indicator plate (3) and tighten it

with the central bolt (2).
NOTE: Adjust the sensor if necessary.
ZDA7016A_152 3
12157 1 02/07/2004
K.42.C / 16
4. Remove the support to unblock the rotary separator.

Install the cover (1).
ZDA7015A_153 4
12157 1 02/07/2004
K.42.C / 17
Drum Shaft - Remove (K.42.C.52.40 - F.10.A.10)

CS540, CS640, CS660
Prior operation: Remove the left-hand side bearing, refer to Drum Left hand bearing - Remove (K.42.C.52.02 -
F.10.A.10).
Prior operation: Remove the right-hand side bearing, refer to Drum Right hand bearing - Remove (K.42.C.52.01
- F.10.A.10) .
1. Enter the grain tank and remove the cover (2), using
the handles.
ZDA6138A 1
2. To have access to the rotary separator, remove the

cover by loosening the bolts.
ZDA6160B 2
3. Loosen the counter nut (1) and the bolt (2) slightly
on both sides.
ZDA7029A 3
12157 1 02/07/2004
K.42.C / 18
4. Support the rotary separator and keep the keys on

the upper side.
Remove the rotary separator shaft (3) to the left or
right.
ZDA7030A 4
12157 1 02/07/2004
K.42.C / 19
Drum Shaft - Install (K.42.C.52.40 - F.10.A.15)

CS540, CS640, CS660
1. Insert the shaft (3) with the keys on the upper side
in the sheaves.
ZDA7030A_157 1
2. Install the left-hand side bearing, refer to Drum Left

hand bearing - Install (K.42.C.52.02 - F.10.A.15).
3. Install the right-hand side bearing, refer to Drum
Right hand bearing - Install (K.42.C.52.01 -
F.10.A.15).
4. Enter the grain tank and adjust the rotary separator
with distance "X" between 9 - 11 mm (3/8 - 14/32
in) at the right-hand side to be measured on the
nearest slat and at the nearest spot.
ZDA7032A 2
5. Tighten the bolt (2) and the counter nut (1) on both
sides with a maximum torque of 30 Nm. (22 lb ft)
ZDA7029A_158 3
6. Install the covers in the grain tank.
12157 1 02/07/2004
K.42.C / 20

(K.42.C.95.50 - G.30.B.53)
CS540, CS640, CS660
E119 - ROTARY SEPARATOR (B11) SENSOR SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty rotary separator sensor
Solution:
1. Check the rotary separator sensor connector X32, CCM connector X141, and the in-line harness
connector X26.

(ZW) and ground. If a short to ground is indicated, remove and replace the rotary separator sensor.


4. Check the rotary separator sensor.
A. Connect connector X141. Remove the rotary separator sensor. Disconnect the straw walker sensor
connector X37. Connect the suspect rotary separator sensor to connector X37. Turn the keystart
ON. Check if the error code E110 is now also displayed. If error code E110 is displayed, replace
the rotary separator sensor.

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12157 1 02/07/2004
K.42.C / 21

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 22
55_a3cs016 1
12157 1 02/07/2004
K.42.C / 23

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 24
vfil04cs0026h0a 2
12157 1 02/07/2004
K.42.C / 25

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 26
vfil04cs0027h0a 3
12157 1 02/07/2004
K.42.C / 27
Sensing system Speed sensor - Short circuit to B+ (K.42.C.95.50 -

G.30.B.54)
CS540, CS640, CS660
E120 - ROTARY SEPARATOR (B11) SENSOR SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the rotary separator sensor connector X32 and the in-line harness connector X26.


(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12157 1 02/07/2004
K.42.C / 28

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 29
55_a3cs016 1
12157 1 02/07/2004
K.42.C / 30

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 31
vfil04cs0026h0a 2
12157 1 02/07/2004
K.42.C / 32

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 33
vfil04cs0027h0a 3
12157 1 02/07/2004
K.42.C / 34
Sensing system Speed sensor - Open circuit (K.42.C.95.50 -

G.30.B.50)
CS540, CS640, CS660
E121 - ROTARY SEPARATOR (B11) SENSOR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty rotary separator sensor
Solution:
1. Check the rotary separator sensor connector X32, CCM connector X141, and the in-line harness connector
X26.


A. Turn the keystart ON. Check between connector X32 pin 2, circuit (080) (GE) and ground. If the voltage

A. Turn the keystart OFF. Remove the rotary separator sensor. Disconnect the straw walker sensor
connector X37. Connect the suspect rotary separator sensor to connector X37. Turn the keystart
the rotary separator sensor.
A. Turn the keystart OFF. Disconnect the connector X141. Check between connector X32 pin 2, circuit
the CCM.
12157 1 02/07/2004
K.42.C / 35

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 36
55_a3cs016 1
12157 1 02/07/2004
K.42.C / 37

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 38
vfil04cs0026h0a 2
12157 1 02/07/2004
K.42.C / 39

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12157 1 02/07/2004
K.42.C / 40
vfil04cs0027h0a 3
12157 1 02/07/2004
K.42.C / 41
Index
CROP PROCESSING - K
Drive system Belt - Install (K.42.C.40.44 - F.10.A.15) 7

CS540, CS640, CS660
Drive system Belt - Remove (K.42.C.40.44 - F.10.A.10) 6
CS540, CS640, CS660
Drum - Exploded view (K.42.C.52 - C.10.A.20) 3
CS540, CS640, CS660
Drum Left hand bearing - Install (K.42.C.52.02 - F.10.A.15) 16
CS540, CS640, CS660
Drum Left hand bearing - Remove (K.42.C.52.02 - F.10.A.10) 14
CS540, CS640, CS660
Drum Right hand bearing - Install (K.42.C.52.01 - F.10.A.15) 11
CS540, CS640, CS660
Drum Right hand bearing - Remove (K.42.C.52.01 - F.10.A.10) 8
CS540, CS640, CS660
Drum Shaft - Install (K.42.C.52.40 - F.10.A.15) 20
CS540, CS640, CS660
Drum Shaft - Remove (K.42.C.52.40 - F.10.A.10) 18
CS540, CS640, CS660
CS540, CS640, CS660
CS540, CS640, CS660
CS540, CS640, CS660
SEPARATING Rotary separator - Install (K.42.C - F.10.A.15) 5
CS540, CS640, CS660
SEPARATING Rotary separator - Remove (K.42.C - F.10.A.10) 4
CS540, CS640, CS660
12157 1 02/07/2004
K.42.C / 42
CROP PROCESSING - K
SEPARATING Straw walker - 42.E
CS540
CS640
CS520
CS660
12158 1 02/07/2004
K.42.E / 1
Contents
CROP PROCESSING - K
TECHNICAL DATA
Straw walker shaft

Straw walker shaft - Special tools (K.42.E.43 - D.20.A.40) 4
CS540, CS640, CS520, CS660
FUNCTIONAL DATA
Front shaft
Front shaft - Exploded view (K.42.E.56 - C.10.A.20) 5
CS540, CS640, CS520, CS660
Rear shaft
Rear shaft - Exploded view (K.42.E.57 - C.10.A.20) 6
CS540, CS640, CS520, CS660
Straw walker
Straw walker Bearing - Detailed view (K.42.E.58.40 - C.10.A.50) 7
CS540, CS520
CS640, CS660
SERVICE
Front shaft
Front shaft - Remove (K.42.E.56 - F.10.A.10) 9
CS540, CS640, CS520, CS660
Front shaft - Install (K.42.E.56 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Rear shaft
Rear shaft - Remove (K.42.E.57 - F.10.A.10) 13
CS540, CS640, CS520, CS660
Rear shaft - Install (K.42.E.57 - F.20.A.20) 16
CS540, CS640, CS520, CS660
Straw walker
Straw walker - Remove (K.42.E.58 - F.10.A.10) 19
CS540, CS640, CS520, CS660
Straw walker - Install (K.42.E.58 - F.10.A.15) 21
CS540, CS640, CS520, CS660
Straw walker Bearing - Remove (K.42.E.58.40 - F.10.A.10) 22
CS540, CS640, CS520, CS660
Straw walker Bearing - Install (K.42.E.58.40 - F.10.A.15) 23
CS540, CS640, CS520, CS660
12158 1 02/07/2004
K.42.E / 2
DIAGNOSTIC
Sensing system
Sensing system Straw walker sensor - Short circuit to ground (K.42.E.95.50 - G.30.B.53) 24
CS540, CS640, CS520, CS660
Sensing system Straw walker sensor - Short circuit to B+ (K.42.E.95.50 - G.30.B.54) 31
CS540, CS640, CS520, CS660
Sensing system Straw walker sensor - Open circuit (K.42.E.95.50 - G.30.B.50) 38
CS540, CS640, CS520, CS660
Sensing system Grain loss sensor - Short circuit to ground (K.42.E.95.52 - G.30.B.53) 45
CS540, CS640, CS520, CS660
Sensing system Grain loss sensor - Short circuit to B+ (K.42.E.95.52 - G.30.B.54) 52
CS540, CS640, CS520, CS660
Sensing system - Short circuit to ground (K.42.E.95 - G.30.B.53) 59
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
12158 1 02/07/2004
K.42.E / 3
CROP PROCESSING - SEPARATING Straw walker
Straw walker shaft - Special tools (K.42.E.43 - D.20.A.40)

CS540, CS640, CS520, CS660
Tool to remove straw walker bearing
ZEIL04CS0109F0B 1
A= Dia.120 mm (4-3/4 in) E= Dia.9 mm (3/8 in)

B= 75 mm (3 in) F= 20 mm (3/4 in)
C= 50 mm (2 in) G= 15 mm (19/32 in)
D= M18x1.5 mm
12158 1 02/07/2004
K.42.E / 4
Front shaft - Exploded view (K.42.E.56 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA6720A 1
Straw walker front shaft
1 Straw walker shaft 2 Bearing

5 Grease cover 6 Pulley
7 Retaining ring 8 Bearing plate
9 Cover 10 Felt ring
11 Cover 12 Key
12158 1 02/07/2004
K.42.E / 5
Rear shaft - Exploded view (K.42.E.57 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA6684A 1
Straw walker rear shaft
1 Straw walker shaft 2 Bearing

5 Grease cover 6 Bearing cover
7 Grease collar 8 Bearing plate
9 Cover 10 Felt ring
11 Cover
12158 1 02/07/2004
K.42.E / 6
Straw walker Bearing - Detailed view (K.42.E.58.40 - C.10.A.50)

CS540, CS520
ZDA4794A 1
model CS500 (5 straw walkers)
A = 125-129 mm (4-59/64 in - 5-5/64 in) B = 386-390 mm (15-3/16 in - 15-11/32 in)

C = 647-651 mm (25-15/32 in - 25-5/8 in) D = 908-912 mm (35-3/4 in - 35-29/32 in)
E = 1169-1173 mm (46-3/128 in - 46-3/16 in) X = 3 mm (1/8 in)
12158 1 02/07/2004
K.42.E / 7
Straw walker Bearing - Detailed view (K.42.E.58.40 - C.10.A.50)

CS640, CS660
ZDA4723A 1
model CS600 (6 straw walkers)
A = 125-129 mm (4-59/64 in - 5-5/64 in) B = 386-390 mm (15-3/16 in - 15-11/32 in)

C = 647-651 mm (25-15/32 in - 25-5/8 in) D = 908-912 mm (35-3/4 in - 35-29/32 in)
E = 1169-1173 mm (46-3/128 in - 46-3/16 in) F = 1430-1434 mm (56-20/64 in - 56-1/2 in)
F = 1430-1434 mm (56-20/64 in - 56-1/2 in)
12158 1 02/07/2004
K.42.E / 8
Front shaft - Remove (K.42.E.56 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Remove the straw walkers, refer to Straw walker - Remove (K.42.E.58 - F.10.A.10), or just
loosen and support them.
1. On the left-hand side, loosen the bolt (1) and the

nut (2).
Loosen the bolt (3) and remove the straw walker
drive belt (4).
ZDA6046B 1

ZDA6678A 2

Remove the four nuts (2) and remove the speed
sensor support (3).
ZDA6677A 3
12158 1 02/07/2004
K.42.E / 9
4. On the right-hand side, loosen the two nuts (1) and

remove the grease cover (2).
ZDA6680A 4
5. Remove the retaining ring(3) and the washer(s).

Loosen the two nuts (4).
ZDA7321A 5
6. To remove the bearing, using the special tool

Straw walker shaft - Special tools (K.42.E.43
- D.20.A.40))
7. Remove the bearing on the left-hand side using a
puller. The shaft can be removed from the inner
side of the machine.
12158 1 02/07/2004
K.42.E / 10
Front shaft - Install (K.42.E.56 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the pre-assembled shaft in the frame.
ZDA4733A 1
2. Install and tighten the two nuts (4).

NOTE: Do not forget to install the plates and the felt ring
between the bearing and the frame.
ZDA7325B 2
3. Install the left-hand side bearing and tighten the nuts

(2). Don’t forget to install the sensor support (3).
ZDA6677A 3
12158 1 02/07/2004
K.42.E / 11
4. Before install the washer(s) (1) and the retaining

ring (2) of the right-hand side bearing, check
the dimension given in Straw walker Bearing -
Detailed view (K.42.E.58.40 - C.10.A.50) and
adjust, if needed.
NOTE: The clearance between the washer(s) (1) and the
retaining ring (2) is maximum 1 mm. (5/128 in )
ZDA4630A 4
5. Install the grease cover (2) at the right-hand side

and tighten them with the two nuts (1).
NOTE: Check if the grease zerk is installed to the rear.
ZDA6680A 5

NOTE: Adjust the speed sensor if necessary.
ZDA6678A 6
7. Grease the bearings on both sides.
Next operation: Install the straw walkers. refer to Straw walker - Install (K.42.E.58 - F.10.A.15).
Next operation: Install the straw walker drive belt and adjust as described in the CS Operator’s manual; "SECTION
4 - LUBRICATION AND MAINTENANCE", paragraph: "Drive belts and chains - Left-hand side".
12158 1 02/07/2004
K.42.E / 12
Rear shaft - Remove (K.42.E.57 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Remove the straw walkers, refer to Straw walker - Remove (K.42.E.58 - F.10.A.10) , or just
loosen and support them.
1. On the left-hand side, if a straw chopper, loosen the

eccentric chopper rear drive idler (1) by turning the
shaft (2), using a spanner of 19 mm. (3/4 in)
ZDA6129A 1
2. Loosen the Allen screw (1) and remove the grease

collar (2).
ZDA6943B 2
3. If a chaff spreader is installed, remove the drive belt

(1), the retaining ring (2), the pulley (3) and the key.
ZDA7312A 3
12158 1 02/07/2004
K.42.E / 13
4. Loosen the four nuts (3) of the bearing housing (4).
ZDA7085A 4
5. On the right-hand side, to have a better access to

the bearing, remove first the shielding (5).
ZDA7322A 5
6. Loosen the two nuts (1) and remove the grease

cover (2).
ZDA6944A 6
7. Remove the retaining ring (3) and the washer(s).

Loosen the two nuts (4).
ZDA7325A 7
12158 1 02/07/2004
K.42.E / 14
8. Push the shaft from the right-hand side bearing, by

moving the shaft to the left.
9. Remove the bearing on the left-hand side, using a
puller. The shaft can be removed from the inner
side of the machine.
12158 1 02/07/2004
K.42.E / 15
Rear shaft - Install (K.42.E.57 - F.20.A.20)

CS540, CS640, CS520, CS660
1. Bring the straw walker shaft (1) in the frame.
ZDA6945A 1
2. Install the right-hand side bearing with the two nuts

(4).
ZDA7325B 2
3. Install the left-hand side bearing and tighten the four

nuts (3) of the bearing housing (4).
ZDA7085A_159 3
12158 1 02/07/2004
K.42.E / 16
4. Do not forget to install the bearing cover (1) on both

sides.
ZDA4719A 4
5. Before install the washer(s) (1) and the retaining

ring (2) of the right-hand side bearing, check
the dimension given in Straw walker Bearing -
Detailed view (K.42.E.58.40 - C.10.A.50) and
adjust, if needed.
NOTE: The clearance between the washers (1) and the
retaining ring (2) is maximum 1 mm. (5/128 in)
ZDA4630A_160 5
6. Install the grease cover (2) and tighten them with

the nuts (1).
ZDA6944A_161 6
7. At the left-hand side install the grease collar (2) and

tighten it with the Allen screw (1).
Grease the bearings on both sides.
ZDA6943B_162 7
12158 1 02/07/2004
K.42.E / 17
8. If a chaff spreader is installed, install the key, the

pulley (3), the retaining ring (2) and the drive belt (1).
ZDA7312A 8
9. If a straw chopper, install the rear chopper drive

belt by turning the shaft (2), using a spanner of 19
mm. (3/4 in)
ZDA6129A 9
Next operation: Install the straw walkers. refer to Straw walker - Install (K.42.E.58 - F.10.A.15).
12158 1 02/07/2004
K.42.E / 18
Straw walker - Remove (K.42.E.58 - F.10.A.10)

CS540, CS640, CS520, CS660
CS500 model: 5 straw walkers.

CS600 model: 6 straw walkers.
Proceed as follows:
1. Remove first the sieves to avoid damage.

2. Inside the straw hood, disconnect the wires of the
straw walker loss sensors.
ZDA6679A 1
3. If a straw chopper is installed, disconnect the

connector (1) from the straw walker security (2).
ZDA7318A 2
4. Remove the cover at the rear of the straw hood,

using the special tool, located at the left-hand side
of the straw elevator.
ZDA6689B 3
12158 1 02/07/2004
K.42.E / 19
5. One by one loosen the nuts (2) of the straw walkers

from the bearing assembly.
ZDA6676A 4
6. Slide the straw walker out through the opening in

the straw hood. The weight of the straw walker is
about 40 kg. (90 lb)
NOTE: To prevent damage, hang-up the straw walker
security (3) while removing the straw walkers.
ZDA7317A 5
12158 1 02/07/2004
K.42.E / 20
Straw walker - Install (K.42.E.58 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Slide the straw walkers in through the opening of

the straw hood.
2. Adjust the outer straw walkers with dimension "X"
between 8 - 12 mm. (5/16 - 1/2 in)
ZDA7676A 1
3. Tighten the nuts (2) of the straw walker bearing

assembly.
ZDA6676A 2
4. The distance between the straw walkers must be

divided equally. Maximum difference allowed is 3
mm (1/8 in).
ZDA7025A 3
5. Close the cover of the straw hood, using the special

tool.
6. Connect the wires of the straw walker loss sensors
and the straw walker security. (if a straw chopper
is installed)
7. Install the sieves. Refer to the CS operator’s
manual; "SECTION 3 - FIELD AND SITE
OPERATION"; paragraph headed: "Sieves".
12158 1 02/07/2004
K.42.E / 21
Straw walker Bearing - Remove (K.42.E.58.40 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Refer to Front shaft - Remove (K.42.E.56 - F.10.A.10) or Rear shaft - Remove (K.42.E.57 -
F.10.A.10).
1. Loosen the four nuts (1) and remove the bolts.
ZDA4734A 1
2. Lift the lips of the locking washer (2) out of the slots
of the nut (3).
Loosen and remove the nut (3).
ZDA4718A 2
3. Remove the locking washer (2).

Remove the bearing from the shaft.
ZDA4720A 3
12158 1 02/07/2004
K.42.E / 22
Straw walker Bearing - Install (K.42.E.58.40 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Remove the grease of the adapter sleeves (1)

before installation.
ZDA4721A 1
2. Tighten the nut (3) to a torque between 100 - 110

Nm. (74-81 lb ft ) and secure with locking washer 2.
NOTE: Check the bearing position related to the shaft
collar, refer to Straw walker Bearing - Detailed view
(K.42.E.58.40 - C.10.A.50).
ZDA4718A_163 2
3. The felt rings (1) must be steeped with engine oil.

Fill up the bearing covers (2) with grease NLGI-2.
Tighten the four nuts (3).
ZDA4624A 3
4. Refer to Front shaft - Install (K.42.E.56 - F.10.A.15)

or Rear shaft - Install (K.42.E.57 - F.20.A.20).
12158 1 02/07/2004
K.42.E / 23
Sensing system Straw walker sensor - Short circuit to ground

(K.42.E.95.50 - G.30.B.53)
CS540, CS640, CS520, CS660
E110 - STRAW WALKER (B13) SENSOR SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty straw walker sensor
Solution:
1. Check the straw walker sensor connector X37, CCM connector X141, and the in-line harness connector X26.

(ZW) and ground. If a short to ground is indicated, remove and replace the straw walker sensor.


4. Check the straw walker sensor.
A. Connect connector X141. Remove the straw walker sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect straw walker sensor to connector X32. Turn the keystart ON.
Check if the error code E119 is now also displayed. If error code E119 is displayed, replace the straw
walker sensor.

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12158 1 02/07/2004
K.42.E / 24

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 25
55_a3cs016 1
12158 1 02/07/2004
K.42.E / 26

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 27
vfil04cs0026h0a 2
12158 1 02/07/2004
K.42.E / 28

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 29
vfil04cs0027h0a 3
12158 1 02/07/2004
K.42.E / 30
Sensing system Straw walker sensor - Short circuit to B+

(K.42.E.95.50 - G.30.B.54)
CS540, CS640, CS520, CS660
E111 - STRAW WALKER (B13) SENSOR SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the straw walker sensor connector X37 and the in-line harness connector X26.


(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12158 1 02/07/2004
K.42.E / 31

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 32
55_a3cs016 1
12158 1 02/07/2004
K.42.E / 33

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 34
vfil04cs0026h0a 2
12158 1 02/07/2004
K.42.E / 35

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 36
vfil04cs0027h0a 3
12158 1 02/07/2004
K.42.E / 37
Sensing system Straw walker sensor - Open circuit (K.42.E.95.50 -

G.30.B.50)
CS540, CS640, CS520, CS660
E112 - STRAW WALKER (B13) SENSOR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty straw walker sensor
Solution:
1. Check the straw walker sensor connector X37, CCM connector X141, and the in-line harness connector X26.


A. Turn the keystart ON. Check between connector X37 pin 2, circuit (082) (GE) and ground. If the voltage

A. Turn the keystart OFF. Remove the straw walker sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect straw walker sensor to connector X32. Turn the keystart ON.
walker sensor.
A. Turn the keystart OFF. Disconnect the connector X141. Check between connector X37 pin 2, circuit
the CCM.
12158 1 02/07/2004
K.42.E / 38

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 39
55_a3cs016 1
12158 1 02/07/2004
K.42.E / 40

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 41
vfil04cs0026h0a 2
12158 1 02/07/2004
K.42.E / 42

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 43
vfil04cs0027h0a 3
12158 1 02/07/2004
K.42.E / 44
Sensing system Grain loss sensor - Short circuit to ground

(K.42.E.95.52 - G.30.B.53)
CS540, CS640, CS520, CS660
E404 - STRAW WALKER GRAIN LOSS SENSOR (B20) (LEFT HAND SIDE) SHORT TO GROUND OR OPEN
CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty straw walker grain loss sensor
Solution:
1. Check the straw walker left hand grain loss sensor connector X54, CCM connector X142, and the in-line
harness connectors X10, X114 and X153.

A. Disconnect connector X54, . Turn the keystart ON. Check between connector X54, pin 1, circuit (177)
(BL) and ground. If no voltage is indicated, repair or replace the harness as required.

A. Turn the keystart OFF. Disconnect the CCM connector X142. Check between connector X54, pin 2,

A. Check between connector X54 pin 2, circuit (180) (GE) and X142 pin 34, circuit (180) (GE). If an open
B. If the harness is okay, remove and replace the straw walker left hand grain loss sensor. If the fault is still

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12158 1 02/07/2004
K.42.E / 45

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 46
55_a3cs016 1
12158 1 02/07/2004
K.42.E / 47

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 48
vfil04cs0026h0a 2
12158 1 02/07/2004
K.42.E / 49

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 50
vfil04cs0027h0a 3
12158 1 02/07/2004
K.42.E / 51
Sensing system Grain loss sensor - Short circuit to B+ (K.42.E.95.52

- G.30.B.54)
CS540, CS640, CS520, CS660
E405 - STRAW WALKER GRAIN LOSS SENSOR (B20) (LEFT HAND SIDE) SHORT TO CIRCUIT TO +VE
operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the straw walker left hand grain loss sensor connector X54, CCM connector X142, and the in-line

circuit (177) (BL) and ground. If the voltage indicated is greater than +8 Volts, repair or replace the

A. Turn the keystart OFF. Disconnect the CCM connector X142. Turn the keystart ON. Check between
connector X54 pin 2, circuit (180) (GE) and ground. If a voltage is indicated, repair or replace the
B. If the harness is okay, remove and replace the straw walker left hand grain loss sensor. If the fault is still

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12158 1 02/07/2004
K.42.E / 52

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 53
55_a3cs016 1
12158 1 02/07/2004
K.42.E / 54

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 55
vfil04cs0026h0a 2
12158 1 02/07/2004
K.42.E / 56

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 57
vfil04cs0027h0a 3
12158 1 02/07/2004
K.42.E / 58
Sensing system - Short circuit to ground (K.42.E.95 - G.30.B.53)

CS540, CS640, CS520, CS660
E407 - STRAW WALKER GRAIN LOSS SENSOR (B19) (RIGHT HAND SIDE) SHORT TO GROUND OR OPEN
CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the straw walker right hand grain loss sensor connector X53, CCM connector X142, and the in-line

A. Disconnect connector X53. Turn the keystart ON. Check between connector X53, pin 1, circuit (177)
(BL) and ground. If no voltage is indicated, repair or replace the harness as required.


A. Check between connector X53, pin 2, circuit (178) (GE) and X142 pin 35, circuit (178) (GE). If an open
B. If the harness is okay, remove and replace the straw walker right hand grain loss sensor. If the fault is

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12158 1 02/07/2004
K.42.E / 59

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 60
55_a3cs016 1
12158 1 02/07/2004
K.42.E / 61

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 62
vfil04cs0026h0a 2
12158 1 02/07/2004
K.42.E / 63

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 64
vfil04cs0027h0a 3
12158 1 02/07/2004
K.42.E / 65
Sensing system Grain loss sensor - Short circuit to B+ (K.42.E.95.52

- G.30.B.54)
CS540, CS640, CS520, CS660
E408 - STRAW WALKER GRAIN LOSS SENSOR (B19) (RIGHT HAND SIDE) SHORT TO CIRCUIT TO +VE
operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the straw walker right hand grain loss sensor connector X53, CCM connector X142, and the in-line


A. Turn the keystart OFF. Disconnect the CCM connector X142. Turn the keystart ON. Check between
B. If the harness is okay, remove and replace the straw walker right hand grain loss sensor. If the fault is

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12158 1 02/07/2004
K.42.E / 66

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 67
55_a3cs016 1
12158 1 02/07/2004
K.42.E / 68

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 69
vfil04cs0026h0a 2
12158 1 02/07/2004
K.42.E / 70

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12158 1 02/07/2004
K.42.E / 71
vfil04cs0027h0a 3
12158 1 02/07/2004
K.42.E / 72
Index
CROP PROCESSING - K
Front shaft - Exploded view (K.42.E.56 - C.10.A.20) 5

CS540, CS640, CS520, CS660
Front shaft - Install (K.42.E.56 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Front shaft - Remove (K.42.E.56 - F.10.A.10) 9
CS540, CS640, CS520, CS660
Rear shaft - Exploded view (K.42.E.57 - C.10.A.20) 6
CS540, CS640, CS520, CS660
Rear shaft - Install (K.42.E.57 - F.20.A.20) 16
CS540, CS640, CS520, CS660
Rear shaft - Remove (K.42.E.57 - F.10.A.10) 13
CS540, CS640, CS520, CS660
Sensing system - Short circuit to ground (K.42.E.95 - G.30.B.53) 59
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Sensing system Grain loss sensor - Short circuit to ground (K.42.E.95.52 - G.30.B.53) 45
CS540, CS640, CS520, CS660
Sensing system Straw walker sensor - Open circuit (K.42.E.95.50 - G.30.B.50) 38
CS540, CS640, CS520, CS660
Sensing system Straw walker sensor - Short circuit to B+ (K.42.E.95.50 - G.30.B.54) 31
CS540, CS640, CS520, CS660
Sensing system Straw walker sensor - Short circuit to ground (K.42.E.95.50 - G.30.B.53) 24
CS540, CS640, CS520, CS660
Straw walker - Install (K.42.E.58 - F.10.A.15) 21
CS540, CS640, CS520, CS660
Straw walker - Remove (K.42.E.58 - F.10.A.10) 19
CS540, CS640, CS520, CS660
CS540, CS520
CS640, CS660
Straw walker Bearing - Install (K.42.E.58.40 - F.10.A.15) 23
CS540, CS640, CS520, CS660
Straw walker Bearing - Remove (K.42.E.58.40 - F.10.A.10) 22
CS540, CS640, CS520, CS660
Straw walker shaft - Special tools (K.42.E.43 - D.20.A.40) 4
CS540, CS640, CS520, CS660
12158 1 02/07/2004
K.42.E / 73
12158 1 02/07/2004
K.42.E / 74
CROP PROCESSING - K
CLEANING Primary cleaning - 62.B
CS540
CS640
CS520
CS660
12160 1 02/07/2004
K.62.B / 1
Contents
CROP PROCESSING - K
TECHNICAL DATA
CLEANING Primary cleaning - Special tools (K.62.B - D.20.A.40) 4

CS540, CS640, CS520, CS660
FUNCTIONAL DATA
CLEANING Primary cleaning - Static description (K.62.B - C.30.A.20) 5

CS540, CS640, CS520, CS660
Shoe drive system

Shoe drive system - Exploded view (K.62.B.45 - C.10.A.20) 6
CS540, CS640, CS520, CS660
Shoe drive system - Sectional view (K.62.B.45 - C.10.A.30) 7
CS540, CS640, CS520, CS660
SERVICE
Shoe drive system

Shoe drive system Shaft - Remove (K.62.B.45.40 - F.10.A.10) 8
CS540, CS640, CS520, CS660
Shoe drive system Shaft - Install (K.62.B.45.40 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Shoe drive system Belt - Remove (K.62.B.45.44 - F.10.A.10) 15
CS540, CS640, CS520, CS660
Shoe drive system Belt - Install (K.62.B.45.44 - F.10.A.15) 16
CS540, CS640, CS520, CS660
Upper shoe
Upper shoe - Remove (K.62.B.51 - F.10.A.10) 17
CS540, CS640, CS520, CS660
Upper shoe - Install (K.62.B.51 - F.10.A.15) 24
CS540, CS640, CS520, CS660
Fan
Fan Shaft - Remove (K.62.B.52.43 - F.10.A.10) 30
CS540, CS640, CS520, CS660
Fan Shaft - Install (K.62.B.52.43 - F.10.A.15) 33
CS540, CS640, CS520, CS660
Fan Fan housing - Remove (K.62.B.52.70 - F.10.A.10) 36
CS540, CS640, CS520, CS660
Fan Fan housing - Install (K.62.B.52.70 - F.10.A.15) 42
CS540, CS640, CS520, CS660
Fan Deflector - Adjust (K.62.B.52.76 - F.45.A.01) 47
CS540, CS640, CS520, CS660
12160 1 02/07/2004
K.62.B / 2
Fan variator
Fan variator Belt - Remove (K.62.B.53.44 - F.10.A.10) 49
CS540, CS640, CS520, CS660
Fan variator Belt - Install (K.62.B.53.44 - F.10.A.15) 52
CS540, CS640, CS520, CS660
Fan variator Driven disc - Remove (K.62.B.53.51 - F.10.A.10) 55
CS540, CS640, CS520, CS660
Fan variator Driven disc - Disassemble (K.62.B.53.51 - F.10.A.25) 56
CS540, CS640, CS520, CS660
Fan variator Driven disc - Assemble (K.62.B.53.51 - F.10.A.20) 57
CS540, CS640, CS520, CS660
Fan variator Driven disc - Install (K.62.B.53.51 - F.10.A.15) 58
CS540, CS640, CS520, CS660
Grain pan
Grain pan - Remove (K.62.B.58 - F.10.A.10) 59
CS540, CS640, CS520, CS660
Grain pan - Install (K.62.B.58 - F.10.A.15) 61
CS540, CS640, CS520, CS660
Upper sieve levelling system

Upper sieve levelling system - Adjust (K.62.B.64 - F.45.A.01) 62
CS540, CS640, CS520, CS660
DIAGNOSTIC
Command
Command Self-levelling overide switch - Short circuit to ground (K.62.B.05.64 - G.30.B.53) 65
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Upper sieve levelling system

Upper sieve levelling system Command - Short circuit to ground (K.62.B.64.05 - G.30.B.53) 75
CS540, CS640, CS520, CS660
Upper sieve levelling system Command - Short circuit to B+ (K.62.B.64.05 - G.30.B.54) 80
CS540, CS640, CS520, CS660
Upper sieve levelling system Motor - Short circuit to ground (K.62.B.64.58 - G.30.B.53) 85
CS540, CS640, CS520, CS660
Sensing system
Sensing system Fan speed sensor - Short circuit to ground (K.62.B.95.52 - G.30.B.53) 90
CS540, CS640, CS520, CS660
Sensing system Fan speed sensor - Short circuit to B+ (K.62.B.95.52 - G.30.B.54) 97
CS540, CS640, CS520, CS660
Sensing system Fan speed sensor - Open circuit (K.62.B.95.52 - G.30.B.50) 104
CS540, CS640, CS520, CS660
Sensing system Sieve grain loss sensor - Short circuit to ground (K.62.B.95.55 - G.30.B.53) 111
CS540, CS640, CS520, CS660
Sensing system Sieve grain loss sensor - Short circuit to B+ (K.62.B.95.55 - G.30.B.54) 118
CS540, CS640, CS520, CS660
Sensing system Lateral inclination sensor - Short circuit to ground (K.62.B.95.50 - 125
G.30.B.53)
CS540, CS640, CS520, CS660
Sensing system Lateral inclination sensor - Short circuit to B+ (K.62.B.95.50 - G.30.B.54) 130
CS540, CS640, CS520, CS660
12160 1 02/07/2004
K.62.B / 3
CROP PROCESSING - CLEANING Primary cleaning
CLEANING Primary cleaning - Special tools (K.62.B - D.20.A.40)

CS540, CS640, CS520, CS660
Self-levelling upper sieve adjustment tool
ZDF0339A 1
A= 1537 mm (60-1/2 in) J= diameter 6 mm (1/4 in)

B= 116 mm (4-9/16 in) K= 3 x 30 °
C= 1574 mm (61-31/32 in) L= diameter 9.2 mm (3/8 in)
D= 30 mm (1-3/16 in) M= 23 mm (29/32 in)
E= 25 mm (1 in) N= diameter 18 mm (3/4 in)
F= 7 mm (1/4 in) O= diameter 8 mm (5/16 in)
G= 4.5 mm (3/16 in) P= radius 10 mm (3/8 in)
H= 2.75 mm (1/8 in) Q= O-ring (9.19 x2.62 mm) (3/8 in x 1/8 in)
I= Metric 12 mm R= nut Metric 12 mm
12160 1 02/07/2004
K.62.B / 4
CLEANING Primary cleaning - Static description (K.62.B - C.30.A.20)

CS540, CS640, CS520, CS660
ZDF0359A 1
1 Grain pan 2 Cleaning fan

3 Cleaning fan housing 4 Pre-sieve (only fixed cleaning system)
5 Upper sieve 6 Upper shaker shoe
7 Lower sieve 8 Bottom shaker shoe
9 Clean grain cross auger 10 Returns cross auger
12160 1 02/07/2004
K.62.B / 5
Shoe drive system - Exploded view (K.62.B.45 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDF0271A 1
1 Eccentric shaft 2 Key

3 Key 4 Retaining ring
7 Bolt 8 Washer
9 Nut
12160 1 02/07/2004
K.62.B / 6
Shoe drive system - Sectional view (K.62.B.45 - C.10.A.30)

CS540, CS640, CS520, CS660
ZDF0272A 1
1 Eccentric shaft 2 Key

3 Key 4 Pulley (left-hand side)
7 Pulley (right-hand side) 8 Grease tube
9 Eccentric block
12160 1 02/07/2004
K.62.B / 7
Shoe drive system Shaft - Remove (K.62.B.45.40 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: At the right-hand side, remove the cleaning fan variator drive belt. Refer to Fan variator Belt -
Remove (K.62.B.53.44 - F.10.A.10) .
1. Loosen the nut (2) to release the cleaning shoe

drive belt (1).
ZDA7264A 1
2. Remove the bolt (3) and the washers.

ZDF0243A 2
3. At the left-hand side, remove the shielding (1) by

ZDA6052C 3
12160 1 02/07/2004
K.62.B / 8
4. Remove the shielding (2) by loosening the bolts.
ZDA7604A_169 4

Remove the straw walker belt (2).
Remove the support (1) completely.
ZDA7605B 5
6. Release the nut (4) completely to remove the grain

cross auger and elevator drive belt.
ZDA7606A 6
7. Loosen the central bolt (3) and remove the pulley

(4), using a puller.
ZDF0301A 7
12160 1 02/07/2004
K.62.B / 9
8. On both sides, remove the two bolts (2) from the

eccentric drive rod of the combine.
ZDA7652A 8
9. Remove the grease tube (1).
ZDF0262B 9

Install two threaded rods (Metric 8) onto the holes
(10) and remove the eccentric blocks by using a
special puller.
Remove the key (3).
ZDF0269A 10
11. Remove the three bolts (7) of the bearing housings

(6) and turn them so that they can pass trough the
holes in the frame.
ZDF0268A 11
12160 1 02/07/2004
K.62.B / 10
Shoe drive system Shaft - Install (K.62.B.45.40 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the pre-assembled bearing housings (6) onto

the shaft (1).
NOTE: At the right-hand side, install the bearing (5) on
the ruff of the shaft. This is the side where the shaft is
not marked (X).
2. Install the shaft (1) with the pre-assembled bearing
housings (6) in the frame until the housing can be
fixed with the three bolts (7).
ZDF0268A_170 1
3. On both sides, install the bolts, the washers and

tighten the three nuts (9).
IMPORTANT: Check that the mark (X) on the shaft is
installed to the left-hand side. (see also Shoe drive
system - Sectional view (K.62.B.45 - C.10.A.30))
ZDF0273A 2
4. Install the keys (2) and (3) of the eccentric shaft.

Press the eccentric block (10) onto the shaft.
NOTE: When assembling the both eccentric blocks, be
sure that they are pressed onto the tapered part of the
eccentric shaft.
ZDF0274B 3
5. Install the grease tube (1).
12160 1 02/07/2004
K.62.B / 11
6. Install the eccentic drive rods and tighten the two

bolts (2).
NOTE: Reinstall the shims as they were installed. (LHS
and RHS are different)
ZDA7652A_171 4
7. On the right-hand side, install the pulley (4), the

washers and tighten the central bolt (3).
NOTE: No clearance should be exist between the
eccentrics and the pulley (4).
ZDF0243A_172 5
8. Install the cleaning shoe drive belt (1) and adjust

with the nut (2) as described in the CS Operator’s
manual "SECTION 4 - LUBRICATION AND
MAINTENANCE" ; “Belts and chains".
ZDA7264A 6
9. Install the cleaning fan variator drive belt. Refer

to Fan variator Belt - Install (K.62.B.53.44 -
F.10.A.15).
12160 1 02/07/2004
K.62.B / 12
ZDA7603A 7
11. On the left-hand side, install the pulley (4), the

washer and tighten with the central bolt (3).
NOTE: No clearance should be exist between the
eccentrics and the pulley (4).
ZDF0301A_173 8
12. Install and adjust the grain cross auger and elevator
drive belt by tighten the nut (4). Refer to the CS
Operator’s manual: "SECTION 4 - LUBRICATION
AND MAINTENANCE"; paragraph headed: "Belts
and chains".
ZDA7606A_174 9
13. Install the support (1).

Install and adjust the straw walker drive belt (2).
Refer to the CS Operator’s manual: "SECTION 4 -
LUBRICATION AND MAINTENANCE"; paragraph
headed: "Belts and chains".
Install the shielding (3) and tighten the bolts.
ZDA7605B_175 10
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K.62.B / 13
ZDA7604A_176 11
ZDA6052C_177 12
12160 1 02/07/2004
K.62.B / 14
Shoe drive system Belt - Remove (K.62.B.45.44 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Remove the cleaning fan variator drive belt. Refer to Fan variator Belt - Remove (K.62.B.53.44 -
F.10.A.10).
1. Loosen the nut (2) to release the belt (1).
ZDA7264A 1
2. Remove the belt (1).
12160 1 02/07/2004
K.62.B / 15
Shoe drive system Belt - Install (K.62.B.45.44 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install a new belt (1).

Adjust the belt tension with the nut (2). Refer
to the CS Operator’s Manual; “SECTION 4 -
“LUBRICATION AND MAINTENANCE". Paragraph
ZDA7264A 1
Next operation: Refer to Fan variator Belt - Install (K.62.B.53.44 - F.10.A.15).
12160 1 02/07/2004
K.62.B / 16
Upper shoe - Remove (K.62.B.51 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the chaff spreader (if installed).

2. Remove the upper, lower sieve(s) and the
pre-sieve (if fixed cleaning shoe). Refer to the CS
Operator’s manual; “SECTION 3 - “FIELD AND
SITE OPERATION".
3. Disconnect the wires (1) of the sieves loss sensor.
ZDA7692A 1
4. At the left-hand side, remove the toolbox (2).
ZDA7694A 2
5. If a chaff spreader was installed, remove the railing

(4) on both sides.
Remove the guards (5) on both sides of the straw
hood.
ZDF0413A 3
12160 1 02/07/2004
K.62.B / 17
6. Remove the two bolts (3) of the hinge joints (4) on

both sides.
ZDA7693A 4
7. At the inside, loosen and screw out the bolts (5)

several turns (+/- 5 mm) (3/16 in) on both sides.
Push the bolts towards the outside, using a hammer.
Remove the hinge joints (4) on both sides.(fig.4)
ZDA7704A 5
8. Remove the two bolts (1) from the drive rod.
ZDA7700A 6
9. At the inside, turn out the bolts (2) several turns on

both sides (+/- 5 mm) (3/16 in).
Push the bolts towards the outside, using a hammer.
Remove the hinge joints (3) on both sides.
ZDA7696A 7
12160 1 02/07/2004
K.62.B / 18
10. Loosen the two bolts (6) on both sides at the rear of
the grain pan.
ZDF0258A 8
11. Loosen the bolts (1) and (2) to remove the rear
suspension arms (3) on both sides.
ZDA7698A 9
12. Take out of the upper shaker shoe.
ZDF0342A 10
13. Remove the two bolts (1) and the hinge joints on
both sides.
ZDA7699A 11
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K.62.B / 19
14. At the inside, loosen the four bolts (2) to remove the
plate (3) on both sides.
ZDA7705A 12
15. At the rear, remove the mounting bolts (4) and (5)
and remove the suspension arms on both sides.
ZDA7697A 13
16. Take out of the bottom shaker shoe.
ZDF0270A 14
17. To remove the pivot arms (2), loosen the three bolts
(1).
ZDF0257A 15
12160 1 02/07/2004
K.62.B / 20
ZDF0266A 16
1 Grain pan 2 Upper shaker shoe

3 Lower shaker shoe 4 Front suspension arm (grain pan)
5 Eccentric rod 6 Pivot arm
7 Rear suspension arm (bottom shaker shoe) 8 Rear suspension arm (upper shaker shoe)
18. Pivot arm (6) (fig.16)
The pivot arm consists of two parts (1) and (2)
pressed together on a rubber bushing. The angle
“X" should be between 68 - 70 ° degrees, is very
important and cannot be changed afterwards.
ZDF0334A 17
12160 1 02/07/2004
K.62.B / 21
19. Distance "A", "B" and "C" = between 1 - 3 mm

(5/128 - 1/8 in)
Distance "D"= To the end of the collar.
Distance "E" = between 52.5 - 54.5 mm (2-1/16 -
2-1/8 in) (Only for CS500)
ZDF0338A 18
20. To assemble the silent bloc in the housing, proceed

as follows:
1. Press the silent bloc (1) in the housing, pushing
on the outer ring (2).
2. Press the arm (3) in the silent bloc while
supporting the inner ring (4) of the silent bloc.
NOTE: This procedure is valid for:
- Upper and central silent bloc on all CS models.
- Lower silent bloc on CS600 model.
ZDF0412A 19
12160 1 02/07/2004
K.62.B / 22
21. Suspension arm (7) (see fig.16)

Distance "Y"= between 40 - 42 mm (1-9/16 -
1-21/32 in)
Distance "Z"= between 71 - 73 mm (2-51/64 - 2-7/8
in)
ZDF0335A 20

Distance "X" = between 49 - 51 mm (1-15/16 - 2 in)
ZDF0336A 21

Distance "Y" = between 7 - 9 mm (1/4 - 11/32 in)
Distance "Z" = between 7.5 - 9.5 mm (19/64 - 3/8 in)
ZDF0337A 22
12160 1 02/07/2004
K.62.B / 23
Upper shoe - Install (K.62.B.51 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the main pivot arms (2) on both sides and

tighten only the three mounting bolts (1) on the
right-hand side.
ZDF0257A_165 1
2. Install the lower shaker shoe and adjust it in the

middle of the frame. Dimension "X" must be even
on both sides.
ZDF0264A 2
3. At the rear, install the suspension arms (6) on both

sides without tightening the mounting bolts (4) and
(5).
ZDA7697A_166 3
12160 1 02/07/2004
K.62.B / 24
4. Install the supports (3) on both sides in the bottom

shaker shoe and tighten the bolts (2).
ZDA7705A 4
5. Connect the support (3) (fig.4) with the pivot arm (2)
without tightening the mounting bolts (1) on both
sides.
6. Install the upper shaker shoe and adjust it in the

middle with regard to the bottom shaker shoe
(maximum tolerance = 3 mm) (1/8 in)
Install the rear suspension arms (3) without
tightening the bolts (1) and (2).
ZDA7698A 6
7. Install the hinge points on both sides and apply

Loctite 242 (OMNIFIT 50M or PERMABOND 113)
onto the bolts (4) and (5).
ZDA7704B 7
12160 1 02/07/2004
K.62.B / 25
8. Check and block the angle "X" of the pivot arm (see
also fig. 1) before tightening the bolt (5), to ensure
the silent bloc is clamped in neutral position.
Tighten the bolts (4) and (5) (fig.9) with a torque
between 140 - 160 Nm. (103 - 118 lb ft)
ZEIL04CS0056A0B 8
9. Install the two bolts (1) on both sides.
ZDF0265A 9
10. On the right-hand side install the eccentric rod (6)

with a spacer (7) of 3 mm (1/8 in) thickness and
tighten the mounting bolts (8).
ZDF0260A 10
11
11. Set the drive rod on the left-hand side in the middle
of their stroke by turning the eccentric shaft (key
groove (1) at 90 ° degrees with the drive rod (6)
as shown).
12160 1 02/07/2004
K.62.B / 26
12. On the right-hand side, the distance "Y" (between

the plate on the rod and the outside diameter of the
hinge point) is 13.5 mm (17/32 in).
ZDF0261A 12
13. On the left-hand side, measure the distance "Z"

between the rod and the outside diameter of the
hinge. The number of the shims to add = "Z"-10.5
mm ("Z" -13/32 in).
ZDF0265B 13
14. On the left-hand side, install and tighten the

mounting bolts (8) from the rod with the hinge and
the spacer(s).
Tighten the bolts (1), (2), (7) and the two nuts (3).
ZDF0259A 14
15. Check if the bottom shaker shoe is in the middle of

the frame, and tighten the bolts (4) and (5) of the
rear suspension arms (6) on both sides.
ZDA7697A_166 15
12160 1 02/07/2004
K.62.B / 27
16. Tighten the bolts (1) and (2) on both sides of the rear
suspension arms (3) from the upper shaker shoe.
IMPORTANT: First tighten the bolts in the round holes,
afterwards the bolts in the slotted holes.
ZDA7698A 16
17. Install the upper, lower sieve(s) and the pre-sieve

(if fixed cleaning shoe). Refer to the CS Operator’s
manual; “SECTION 3 - “FIELD AND SITE
OPERATION".
18. Connect the wires (1) of the sieves loss sensor.
ZDA7692A 17
19. Install the guards (5) on both sides of the straw

hood.
If a chaff spreader was installed, install the railing
(4) on both sides.
ZDF0413A_168 18
12160 1 02/07/2004
K.62.B / 28
20. At the left-hand side, install the toolbox (2).
ZDA7694A 19
21. Install the chaff spreader (if installed).

22. Check if the canvas on front of the upper cleaning
shoe is installed in the correct position.
12160 1 02/07/2004
K.62.B / 29
Fan Shaft - Remove (K.62.B.52.43 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Remove the cleaning fan variator drive belt. Refer to Fan variator Belt - Remove (K.62.B.53.44 -
F.10.A.10).
Prior operation: Remove the fan variator driven disks. Refer to Fan variator Driven disc - Remove (K.62.B.53.51
- F.10.A.10).
1. If installed, remove the fan bottom shield by

ZDA6009A_193 1
2. On the left-hand side remove the shielding (1) by

ZDF0370A 2
3. Loosen the nut (4) completely to release the grain

cross auger and elevator drive belt.
ZDA7606A_184 3
12160 1 02/07/2004
K.62.B / 30
4. Remove the straw walker belt (1) by loosening the

idler (2).
ZDF0275A 4
5. Loosen and remove the central bolt (3) and the

speed indicator support (4).
ZDF0361A 5
6. Loosen and remove the bolts and the nuts (1), the
self tapping screws (2) and remove the lower plate
of the cleaning fan housing to gain access to the fan.
ZDF0373A 6
7. Remove all paint from the fan shaft (3).

Loosen the locknut (4) and the bolt (5) on each of
the three fan collars (6).
ZDF0372Z 7
12160 1 02/07/2004
K.62.B / 31
8. Support the fan from the bottom, through the

opening of the removed lower plate in the housing.
Loosen the Allen screw of the lock collar (1) on
both sides.
Use a punch and a hammer to strike the lock collar
(1) in a counter clockwise direction, to loosen the
collar from the shaft.
Remove the lock collar (1) from the shaft on both
sides.
Remove the nuts (2) of the bearing housing on both
sides.
ZDF0371A 8
9. Add some oil or grease on the fan shaft to ease

removal of the shaft and pull out the fan shaft from
the right-hand side of the machine.
12160 1 02/07/2004
K.62.B / 32
Fan Shaft - Install (K.62.B.52.43 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the fan shaft through the three fan collars,

from the right-hand side.
2. Install the left-hand side bearing onto the fan shaft
(3) and tighten it with the bolts.
Install the lock collar onto the bearing but do not
tighten on this time.
ZDF0407A 1
3. Install the right-hand side bearing and tighten the

two nuts (2).
Install the lock collar (1) onto the bearing but do
not tighten on this time.
ZDF0371A 2
4. Measure the distance "X". (This is the distance

from the fan housing to the end of the taper on the
fan shaft).
The distance “X" should be measure between 275.5
- 277.5 mm. (10-27/32 in - 10-59/64 in)
ZDF0414A 3
12160 1 02/07/2004
K.62.B / 33
5. Install the right-hand bearing collar (1) onto the

bearing. Use a punch and hammer in a clock wise
direction, to tighten the lock collar (1) onto the
bearing.
Secure the lock collar with the Allen screw.
Remove the supports from beneath the fan.
ZDF0371B 4
6. Tighten the bolt (5) on each of the three fan collars

(6).
Tighten the locknuts (4).
ZDF0372A 5
7. Install the lower plate of the cleaning fan housing

and secure with the self tapping screws (2) and the
nuts (1).
Tighten all mounting hardware securely.
ZDF0373A_194 6
8. At the left-hand side, install the speed indicator

support (4) and tighten the central bolt (3).
ZDF0361A_195 7
12160 1 02/07/2004
K.62.B / 34
9. Install the straw walker belt (1) and adjust the belt
by tighten the idler (2). Refer to the CS Operator’s
MAINTENANCE"; paragraph headed: "Belts and
chains".
ZDF0275A_196 8
10. Install and adjust the grain cross auger and elevator
drive belt by tighten the nut (4). Refer to the CS
AND MAINTENANCE"; paragraph headed: "Belts
and chains".
ZDA7606A_184 9
11. Install the shielding (1).
ZDF0370A_197 10
12. If necessary, install the fan bottom shield.
Next operation: Install the fan variator driven disks. Refer to Fan variator Driven disc - Install (K.62.B.53.51 -
F.10.A.15).
Next operation: Install the cleaning fan variator drive belt. Refer to Fan variator Belt - Install (K.62.B.53.44 -
F.10.A.15).
12160 1 02/07/2004
K.62.B / 35
Fan Fan housing - Remove (K.62.B.52.70 - F.10.A.10)

CS540, CS640, CS520, CS660
1. If installed, remove the fan bottom shield by

ZDA6009A 1
2. At the right-hand side, open the cover (1) and lock

them with the lever (2).
ZDA6132A 2
3. Remove the shielding (3), by using the special tool.
ZDA6269B 3
12160 1 02/07/2004
K.62.B / 36
ZDA7603A_180 4
5. Loosen the minimum speed adjusting counter nut

(1) and the nut (2) to the end of the threaded rod.
ZDA7260A 5
6. Enter the cab and turn the ignition key to the

“contact" position. Do not start the engine.
7. Set the safety-on-the-road tumbler switch in
“Transport mode" position.
8. Engage the threshing mechanism without starting
the engine.
9. Press on the fan speed rocker switch to decrease
the speed.
74_cs74-2_11 6
12160 1 02/07/2004
K.62.B / 37
10. Switch off the ignition key.

Now is it possible to remove the belt from the fan
variator driven disks (3).
ZDA7715A 7
11. At the left-hand side, remove the shielding (1) by

ZDA6052C_181 8
ZDA7604A_182 9
ZDA7605A_183 10
12160 1 02/07/2004
K.62.B / 38
14. Disconnect the electrical wires at (1).
ZDA7651A 11
15. Remove the straw walker belt (1).

Loosen the bolts to remove the support (2)
completely.
ZDF0275A 12
16. Loosen the nut (4) completely to release the grain

cross auger and elevator belt.
ZDA7606A_184 13
17. Remove the cotter pin (5), the washer and the pin to
remove the tension bar (6).
ZDA7607A 14
12160 1 02/07/2004
K.62.B / 39
18. Remove the two bolts (2) from the drive rod. (only
at this side of the combine)
ZDA7652A_185 15
19. Loosen the central bolt (3) and remove the pulley
(4), using a puller.
ZDF0301A_186 16
20. Remove the grease tube (1).
ZDF0262B_187 17

Install two threaded rods (Metric 8) in the holes (10)
to remove the eccentric block by using a special
puller.
Remove the key (3).
ZDF0269A_188 18
12160 1 02/07/2004
K.62.B / 40
22. Support the cleaning fan housing, using a adequate

lifting device.
ZDA7649A 19
23. Remove the four bolts (3) on both sides.
ZDA7653A 20
24. Lower the fan housing until the supports (4) are
positioned just under the frame (5). Pull the fan
completely to this side (the side were the eccentric
bar is removed) so that the both supports on the
other side can pass through the eccentric bar. Once
passed, lower the fan housing completely.
ZDA7706A 21
12160 1 02/07/2004
K.62.B / 41
Fan Fan housing - Install (K.62.B.52.70 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the cleaning fan housing onto his place.
ZDF0374A 1
2. Install the bolts (11) on both sides and tighten it.

At the left-hand side, install the keys (2) and (3) on
the eccentric shaft.
Press the eccentric block (10) onto the shaft.
NOTE: When assembling the eccentric block, be sure that
they are pressed onto the tapered part of the eccentric
shaft.
ZDF0274A 2
3. Install the grease tube (1).

4. Install the drive rod and tighten the two bolts (2).
NOTE: Reinstall the shims as they were installed.
ZDA7652A_189 3
12160 1 02/07/2004
K.62.B / 42
5. Install the pulley (4) and tighten with the central

bolt (3).
ZDF0301A_186 4
6. Install the tension bar (6) with the pin and secure
it with the cotter pin (5).
ZDA7607A 5
7. Install and adjust the belt by tighten the nut (4).

LUBRICATION AND MAINTENANCE", paragraph
ZDA7606A_190 6
8. Install the support (2).

Install and adjust the straw walker belt (1). Refer
to the CS Operator’s manual: "SECTION 4 -
ZDF0275A 7
12160 1 02/07/2004
K.62.B / 43
9. Connect the electrical wires at (1).
ZDA7651A 8
ZDA7605A_183 9
ZDA7604A_191 10
ZDA6052C_192 11
12160 1 02/07/2004
K.62.B / 44
13. At the right-hand side, install the variator drive belt

onto the driven disks (3).
ZDA7715A 12
14. Adjust the minimum fan speed with the nut (2).
After adjusting tighten the counter nut (1).
ZDA7260A 13
ZDA7603A_180 14
16. Install the shielding (3), using the special tool.
ZDA6269B 15
12160 1 02/07/2004
K.62.B / 45
17. Close the cover (1) by pulling the lever (2).
ZDA6132A 16
12160 1 02/07/2004
K.62.B / 46
Fan Deflector - Adjust (K.62.B.52.76 - F.45.A.01)

CS540, CS640, CS520, CS660
After the cleaning fan housing is installed in the combine, the position of the deflector plates must be checked.
The cleaning fan consist of two horizontal deflector plates, four wind deflectors on the bottom plate and four
deflector plates on the upper plate. (Only 6 straw walker cleaning shoe)
ZDF0415A 1
Horizontal deflector plates:
X Y Z
39-41 mm (1-1/2 in - 1-5/8 in) 119-121 mm (4-11/16 in - 4-3/4 in) 4-7 mm (5/32 in - 1/4 in)
1. Lower deflector plate:

Loosen the nut (1) and adjust the plate in line with
the hole (2). (or check the dimension "X" as shown
in fig.1)
After adjusting tighten the nut (1).
Upper deflector plate:
Loosen the nut (3) and adjust the plate in line with
the hole (4). (or check the dimension “Y" as shown
in fig.1)
After adjusting tighten the nut (3).
ZDA7532A 2
12160 1 02/07/2004
K.62.B / 47
ZDA7533A 3
Deflectors on the upper plate: (Only 6 straw walker - cleaning shoe)
K L M N
299-301 mm (11-3/4 in - 299-301 mm (11-3/4 in - 499-501 mm (19-5/8 in - 499-501 mm (19-5/8 in -
11-27/32 in) 11-27/32 in) 19-3/4 in) 19-3/4 in)
ZDA7531A 4
Deflectors on the bottom plate:
Model A B C D
5-straw walker - 195-197 mm (7-11/16 204-206 mm 414-416 mm 414-416 mm
cleaning shoe in - 7-6/8 in) (8-1/32 in - 8-1/8 (16-19/64 in - 16-3/8 (16-19/64 in - 16-3/8
in) in) in)
6-straw walker - 299-301 mm (11-3/4 in 299-301 mm 499-501 mm (19-5/8 499-501 mm (19-5/8
cleaning shoe -11-27/32 in) (11-3/4 in - in - 19-3/4 in) in - 19-3/4 in)
11-27/32 in)
12160 1 02/07/2004
K.62.B / 48
Fan variator Belt - Remove (K.62.B.53.44 - F.10.A.10)

CS540, CS640, CS520, CS660

and set the fan speed to minimum.
2. Switch off the threshing mechanism.
3. Stop the engine.
CAUTION
stopped rotating
4. Open the right-hand side shielding.

5. Open the cover (1) and lock them with the lever (2).
ZDA6132A 1
6. Remove the shielding (3), by using the special tool.
ZDA6269B 2
12160 1 02/07/2004
K.62.B / 49
7. Remove the minimum speed adjusting counter nut

(1) and the nut (2) completely.
ZDA7260A 3

9. Set the safety-on-the-road tumbler switch in
“transport mode" position.
the engine.
11. Press on the fan speed rocker switch to decrease
the speed.
Switch off the ignition key.
74_cs74-2_06 4

Remove the variator arm (4) completely.
ZDA7261A 5
12160 1 02/07/2004
K.62.B / 50
13. Remove the bearing (5) and the felt ring.

Remove the outer variator sheave (6).
ZDA7262A 6
14. Now is it possible to remove the fan variator belt (7).
ZDA7263A 7
12160 1 02/07/2004
K.62.B / 51
Fan variator Belt - Install (K.62.B.53.44 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install a new belt (7).
ZDA7263A 1
2. Before install the outer variator sheave (6), apply

molybdenum sulphate grease.
Install the bearing (5).
NOTE: The felt rings must be steeped with engine oil.
ZDA7262A 2
3. Install the pre-assembled variator arm (4) with the

bolt (3). (Do not tighten the bolt.)
Align the speed adjustment threaded rod (1), with
the speed adjustment support (2).
ZDA7261B 3

5. Set the safety-on-the-road tumbler switch in the
“Field mode" position.
the engine.
12160 1 02/07/2004
K.62.B / 52
7. Press on the fan speed rocker switch to increase

the speed.
NOTE: Check, if the bearing is properly fitted in the
housing.
74_cs74-2_11 4
8. Install the minimum adjusting speed nut (2).
ZDA7260B 5
9. Adjust the fan variator, refer to the CS Operator’s

Manual: "SECTION 4 - LUBRICATION AND
MAINTENANCE"; paragraph headed: "Cleaning fan
variator belt".
10. After adjusting install and tighten the both counter
nuts (1) and (3).
ZDA7260C 6
12160 1 02/07/2004
K.62.B / 53
11. Tighten the bolt (3).
ZDA7261C 7
12. Install the shielding (3), using the special tool.
ZDA6269B_178 8
13. Close the cover (1) by pulling the lever (2).
ZDA6132A_179 9
12160 1 02/07/2004
K.62.B / 54
Fan variator Driven disc - Remove (K.62.B.53.51 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Remove the fan variator drive belt. Refer to Fan variator Belt - Remove (K.62.B.53.44 -
F.10.A.10) .
1. Remove the grease zerk (1), the nut (2) and the
washer (3).
ZDA7266A 1
2. Use a suitable puller attached to the inner sheave

(4), to unseat the outer sheave (5) from the tapered
shaft.
ZDA7267A 2
12160 1 02/07/2004
K.62.B / 55
Fan variator Driven disc - Disassemble (K.62.B.53.51 - F.10.A.25)

CS540, CS640, CS520, CS660
Prior operation: Remove the fan variator disks. Refer to Fan variator Driven disc - Remove (K.62.B.53.51
- F.10.A.10)
1. Loosen the three nuts (1) to release the spring (3).

Remove the pressure plate (2) and the spring (3).
Now is it possible to remove the inner sheave (4).
ZDA7268A 1
2. Remove the three nuts (5).

Remove the three threaded rods (6).
ZDA7256A 2
12160 1 02/07/2004
K.62.B / 56
Fan variator Driven disc - Assemble (K.62.B.53.51 - F.10.A.20)

CS540, CS640, CS520, CS660
1. Screw the three threaded rods (6) completely (full

depth) in the outer sheave.
Install and tighten the three nuts (5) with a minimum
torque of 110 Nm. (81 lb ft)
ZDA7256A 1
2. Install the outer sheave (4).

Install the spring (3), the pressure plate (2) and
tighten the spring with the three nuts (1). The
distance "X" should be between 145 - 149 mm.
(5-3/4 - 5-7/8 in)
ZDA7258A 2
12160 1 02/07/2004
K.62.B / 57
Fan variator Driven disc - Install (K.62.B.53.51 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the pre-assembled variator driven sheave

onto the shaft (1).
IMPORTANT: Be aware that the cone and the thread of
the shaft (1) and the cone of the outer sheave are free
of grease during assembly.
ZDA7259A 1
2. Install the washer (3) and the nut (2).

After tighten the nut (2), beat-up on the cone and
tighten again.
The torque of the nut (2) should be between 190 -
210 Nm. (140 - 155 ft.lbs)
Install the grease zerk (1) and grease the variator.
ZDA7266A 2
Next operation: Install the fan variator drive belt. Refer to Fan variator Belt - Install (K.62.B.53.44 - F.10.A.15) .
12160 1 02/07/2004
K.62.B / 58
Grain pan - Remove (K.62.B.58 - F.10.A.10)

CS540, CS640, CS520, CS660
IMPORTANT: In case of a self-levelling system, set the combine in a horizontal position. Switch on the ignition
switch and engage the threshing mechanism. The divider plates on the grain pan must come in a position parallel to
the machine frame and the sieve sections must come in a horizontal position.
1. Remove the sieves.
2. Remove the straw elevator. Refer to the CS
Operator’s Manual; “SECTION 3 - FIELD AND SITE
OPERATION": paragraph headed: “Straw elevator -
3. Open the pivot plate (3) (slide the left and the
right-hand lever (4) towards the centre of the stone
trap).
ZDA6006A 1
4. Loosen the two bolts (5) at the front.

NOTE: Use a screw driver between the two supports to
unclamp the removable grain pan.
ZDA6015A 2
5. Take out of the removable grain pan section, pull it

towards the front to remove it.
ZDA6034A 3
12160 1 02/07/2004
K.62.B / 59
6. Loosen the two bolts (1) on the left and right-hand

front side of the main grain pan.
ZDF0263A 4
7. Loosen the two bolts (6) on the left and right-hand

rear side of the grain pan. (connection with the
upper cleaning shoe)
ZDF0258A 5
8. In case of a self-levelling system disconnect the

wires of the actuator.
9. Take out of the main grain pan to the front.
12160 1 02/07/2004
K.62.B / 60
Grain pan - Install (K.62.B.58 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the grain pan in the middle of the frame in line

with the upper shaker shoe. (maximum tolerance
= 3 mm) (1/8 in).
2. Set the eccentric drive rod in the middle of their
stroke by turning the eccentric shaft (key groove (1)
at 90 ° degrees with the drive rod (6) as shown).
ZDF0262A 1
3. Install and tighten the two bolts (6) on both sides at

the rear of the grain pan.
ZDF0258A_164 2
4. Adjust the rubber bushings without forcing and

tighten the two bolts (1) on both sides.
ZDF0263A 3
12160 1 02/07/2004
K.62.B / 61
Upper sieve levelling system - Adjust (K.62.B.64 - F.45.A.01)

CS540, CS640, CS520, CS660
If any parts of the upper sieve has to be replaced, re-adjusting of the sieve will be necessary.
1. Place the combine on a level surface.

2. Remove the bolt (1) to disconnect the actuator.
ZDA6263B 1
3. Adjust the divider plates on the grain pan parallel

with the machine frame. The four holes (2) should
be in line.
ZDF0343A 2
4. Install the special tool (3) as shown. The pin (4)

should just touch the leaf spring (5). (Special
tool:CLEANING Primary cleaning - Special tools
(K.62.B - D.20.A.40))
ZDF0340A 3
12160 1 02/07/2004
K.62.B / 62
5. Measure the distance "X".

Install the upper sieve completely to the front and
measure in this position the new distance "X1".
The difference X-X1 should be between 38 - 40 mm
(1-1/2 - 1-9/16 in).
ZDF0344A 4
6. This distance can be adjusted by adding or

removing shims at (6).
ZDF0341A 5
7. The sieve sections must be parallel with the

machine frame.
Loosen the two nuts (7), use the special tool
CLEANING Primary cleaning - Special tools
(K.62.B - D.20.A.40) and adjust the sections parallel
while the sieve is installed.
After adjusting tighten the nuts (7) by using the
special tool.
ZDF0341B 6
8. Set the ignition key on and engage the threshing

mechanism. The actuator is adjusting itself to a
neutral position.
12160 1 02/07/2004
K.62.B / 63
9. If necessary, adjust the length of the rod (2) by

screwing in or out, until it is possible to install the
actuator with the bolt (1).
ZDA6263D 7
10. Install the pin (3) as shown (from the rear to the
front) so the grain pan dividers are linked to the
system.
Secure with the hair cotter pin (2).
ZDA6263A 8
12160 1 02/07/2004
K.62.B / 64
Command Self-levelling overide switch - Short circuit to ground

(K.62.B.05.64 - G.30.B.53)
CS540, CS640, CS520, CS660
E504 - SELF-LEVELLING OVERRIDE SWITCH (S26) (LEFT HAND SIDE) SHORT TO GROUND
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty self-levelling override switch
Solution:
1. Check the self-levelling override switch connector, CCM connector X141, the self-levelling override switch
connector S26, and the in-line harness connector X24.

A. Disconnect the self-levelling override switch connector S26, and CCM connector X141. Check between
connector S26, pin 3, circuit (093) (WT) and ground. If a short to ground is indicated, repair or replace
the CCM.

(A.30.A - C.20.E.13)
CS540 1260 > 1324
CS640 1260 > 1324

12160 1 02/07/2004
K.62.B / 65

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 66
vfil04cs0022h0a 1
12160 1 02/07/2004
K.62.B / 67

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 68
vfil04cs0023h0a 2
12160 1 02/07/2004
K.62.B / 69
Command Self-levelling overide switch - Short circuit to ground

(K.62.B.05.64 - G.30.B.53)
CS540, CS640, CS520, CS660
E505 - SELF-LEVELLING OVERRIDE SWITCH (S26) (RIGHT HAND SIDE) SHORT TO GROUND
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty self-levelling override switch
Solution:
1. Check the self-levelling override switch connector S26, CCM connector X141 and the in-line harness
connector X24.

A. Disconnect the self-levelling override switch connector S26 and CCM connector X141. Check between
connector S26 pin 1, circuit (092) (GR) and ground. If a short to ground is indicated, repair or replace the
the CCM.

(A.30.A - C.20.E.13)
CS540 1260 > 1324
CS640 1260 > 1324

12160 1 02/07/2004
K.62.B / 70

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 71
vfil04cs0022h0a 1
12160 1 02/07/2004
K.62.B / 72

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 73
vfil04cs0023h0a 2
12160 1 02/07/2004
K.62.B / 74
Upper sieve levelling system Command - Short circuit to ground

(K.62.B.64.05 - G.30.B.53)
CS540, CS640, CS520, CS660
E509 - SELF-LEVELLING ACTUATOR POTENTIOMETER (R1) SHORT TO GROUND OR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty self-levelling actuator potentiometer
Solution:
1. Check the self-levelling actuator potentiometer connector X158, CCM connector X142, and the in-line harness
connector X24.

A. Disconnect connector X158. Check between connector X158 pin 3, circuit (088) (BL) and ground. If an

A. Turn the keystart ON. Check between connector X158 pin 1, circuit (086) (PK) and ground. If the voltage


A. Check between connector X158 pin 2, circuit (087) (GE) and X142 pin 32 circuit (087) (GE). If an open
B. If the harness is okay, remove and replace the self-levelling actuator. If the fault is still present, download
12160 1 02/07/2004
K.62.B / 75

(A.30.A - C.20.E.13)
CS540 1260 > 1324
CS640 1260 > 1324

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 76
vfil04cs0022h0a 1
12160 1 02/07/2004
K.62.B / 77

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 78
vfil04cs0023h0a 2
12160 1 02/07/2004
K.62.B / 79
Upper sieve levelling system Command - Short circuit to B+

(K.62.B.64.05 - G.30.B.54)
CS540, CS640, CS520, CS660
E510 - SELF-LEVELLING ACTUATOR POTENTIOMETER (R1) SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty self-levelling actuator potentiometer
Solution:
1. Check the self-levelling actuator potentiometer connector X158, CCM connector X142, and the in-line harness
connector X24.


A. Turn the keystart OFF. Disconnect connector X142. Turn the keystart ON. Check between connector
X158 pin 1, circuit (087) (GE) and ground. If a voltage is indicated, repair or replace the harness as
required.

(A.30.A - C.20.E.13)
CS540 1260 > 1324
CS640 1260 > 1324

12160 1 02/07/2004
K.62.B / 80

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 81
vfil04cs0022h0a 1
12160 1 02/07/2004
K.62.B / 82

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 83
vfil04cs0023h0a 2
12160 1 02/07/2004
K.62.B / 84
Upper sieve levelling system Motor - Short circuit to ground

(K.62.B.64.58 - G.30.B.53)
CS540, CS640, CS520, CS660
E521 - SELF-LEVELLING ACTUATOR (M6) OUTPUT OPEN OR SHORT CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty self levelling actuator
Solution:
1. Check the self-levelling actuator connector X157, CCM connector X142, and the in-line harness connectors
X24, X113, X115 and X157.

A. Disconnect connector X157 and connector X142. Turn the keystart ON. Measure the voltage between
connector:
X157 pin 1, circuit (089) (BL) and ground
If a voltage is indicated, repair or replace the harness as required

A. Turn the keystart OFF. Check between connector:

X157 pin 1, circuit (089) (BL) and ground


X157 pin 1, circuit (089) (BL) and X142 pin 19, circuit (089) (BL)
X157 pin 1, circuit (089) (BL) and X142 pin 20, circuit (089) (BL)
X157 pin 2, circuit (090) (WT) and X142 pin 39, circuit (090) (WT)
X157 pin 2, circuit (090) (WT) and X142 pin 40, circuit (090) (WT)
12160 1 02/07/2004
K.62.B / 85

(A.30.A - C.20.E.13)
CS540 1260 > 1324
CS640 1260 > 1324

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 86
vfil04cs0022h0a 1
12160 1 02/07/2004
K.62.B / 87

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 88
vfil04cs0023h0a 2
12160 1 02/07/2004
K.62.B / 89
Sensing system Fan speed sensor - Short circuit to ground

(K.62.B.95.52 - G.30.B.53)
CS540, CS640, CS520, CS660
E107 - FANSPEED SENSOR (B8) SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty fan speed sensor
Solution:
1. Check the fan speed sensor connector X28, CCM connector X142, and the in-line harness connector X26.

(ZW) and ground. If a short to ground is indicated, remove and replace the fan speed sensor.

A. Disconnect the connector X142. Check between connector X28 pin 2, circuit (101) (GE) and ground. If a

4. Check the fan speed sensor.
A. Connect connector X142. Remove the fan speed sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect fan speed sensor to connector X32. Turn the key start ON. Check if
the error code E119 is now also displayed. If error code E119 is displayed, replace the fan speed sensor.

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12160 1 02/07/2004
K.62.B / 90

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 91
55_a3cs016 1
12160 1 02/07/2004
K.62.B / 92

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 93
vfil04cs0026h0a 2
12160 1 02/07/2004
K.62.B / 94

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 95
vfil04cs0027h0a 3
12160 1 02/07/2004
K.62.B / 96
Sensing system Fan speed sensor - Short circuit to B+ (K.62.B.95.52

- G.30.B.54)
CS540, CS640, CS520, CS660
E108 - FANSPEED SENSOR (B8) SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the fan speed sensor connector X28 and the in-line harness connector X26.


(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12160 1 02/07/2004
K.62.B / 97

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 98
55_a3cs016 1
12160 1 02/07/2004
K.62.B / 99

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 100
vfil04cs0026h0a 2
12160 1 02/07/2004
K.62.B / 101

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 102
vfil04cs0027h0a 3
12160 1 02/07/2004
K.62.B / 103
Sensing system Fan speed sensor - Open circuit (K.62.B.95.52 -

G.30.B.50)
CS540, CS640, CS520, CS660
E109 - FANSPEED SENSOR (B8) OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty fan speed sensor
Solution:
1. Check the fan speed sensor connector X28, CCM connector X142, and the in-line harness connector X26.



A. Turn the key start OFF. Remove the fan speed sensor. Disconnect the rotary separator sensor connector
X32. Connect the suspect fan speed sensor to connector X32. Turn the key start ON. Check if the error
code E121 is now also displayed. If error code E121 is displayed, replace the fan speed sensor.
the CCM.
12160 1 02/07/2004
K.62.B / 104

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 105
55_a3cs016 1
12160 1 02/07/2004
K.62.B / 106

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 107
vfil04cs0026h0a 2
12160 1 02/07/2004
K.62.B / 108

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 109
vfil04cs0027h0a 3
12160 1 02/07/2004
K.62.B / 110
Sensing system Sieve grain loss sensor - Short circuit to ground

(K.62.B.95.55 - G.30.B.53)
CS540, CS640, CS520, CS660
E401 - SIEVES GRAIN LOSS SENSOR (B21) SHORT TO GROUND OR OPEN CIRCUIT
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty sieves grain loss sensor
Solution:
1. Check the sieves grain loss sensor connector X55, CCM connector X142, and the in-line harness connectors
X10 and X114.

A. Disconnect connector X55. Turn the key start ON. Check between connector X55 pin 1, circuit (177) (BL)
and ground. If no voltage is indicated, repair or replace the harness as required.

A. Turn the key start OFF. Disconnect the CCM connector X142. Check between connector X55 pin 2,

A. Check between connector X55 pin 2, circuit (182) (GE) and X142 pin 33, circuit (182) (GE). If an open
B. If the harness is okay, remove and replace the sieves grain loss sensor. If the fault is still present,

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12160 1 02/07/2004
K.62.B / 111

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 112
55_a3cs016 1
12160 1 02/07/2004
K.62.B / 113

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 114
vfil04cs0026h0a 2
12160 1 02/07/2004
K.62.B / 115

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 116
vfil04cs0027h0a 3
12160 1 02/07/2004
K.62.B / 117
Sensing system Sieve grain loss sensor - Short circuit to B+

(K.62.B.95.55 - G.30.B.54)
CS540, CS640, CS520, CS660
E402 - SIEVES GRAIN LOSS SENSOR (B21) SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty sieves grain loss sensor
Solution:
1. Check the sieves grain loss sensor connector X55, CCM connector X142, and the in-line harness connectors
X10 and X114.


A. Turn the key start OFF. Disconnect the CCM connector X142. Turn the key start ON. Check between
B. If the harness is okay, remove and replace the sieves grain loss sensor. If the fault is still present,

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12160 1 02/07/2004
K.62.B / 118

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 119
55_a3cs016 1
12160 1 02/07/2004
K.62.B / 120

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 121
vfil04cs0026h0a 2
12160 1 02/07/2004
K.62.B / 122

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12160 1 02/07/2004
K.62.B / 123
vfil04cs0027h0a 3
12160 1 02/07/2004
K.62.B / 124
Sensing system Lateral inclination sensor - Short circuit to ground

(K.62.B.95.50 - G.30.B.53)
CS540, CS640, CS520, CS660
E506 - INCLINOMETER (A2) SHORT TO GROUND OR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty inclinometer
Solution:
1. Check the inclinometer connector X23, CCM connector X142, and the in-line harness connectors X111
and X190.

A. Disconnect connector X23. Check between connector X23 pin B, circuit (088) (BL) and ground. If an

A. Turn the key start ON. Check between connector X23 pin A, circuit (086) (PK) and ground. If the voltage

A. Turn the key start OFF. Disconnect the CCM connector X142. Check between connector X23 pin C,

A. Check between connector X23 pin C, circuit (032) (GE) and X142 pin 31 circuit (032) (GE). If an open
B. If the harness is okay, remove and replace the inclinometer. If the fault is still present, download the
correct level of software. If the fault re-occurs, remove and replace the CCM.
12160 1 02/07/2004
K.62.B / 125

(A.30.A - C.20.E.13)
CS540 1260 > 1324
CS640 1260 > 1324

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 126
vfil04cs0022h0a 1
12160 1 02/07/2004
K.62.B / 127

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 128
vfil04cs0023h0a 2
12160 1 02/07/2004
K.62.B / 129
Sensing system Lateral inclination sensor - Short circuit to B+

(K.62.B.95.50 - G.30.B.54)
CS540, CS640, CS520, CS660
E507 - INCLINOMETER (A2) SHORT CIRCUIT TO +VE
operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty inclinometer
Solution:
1. Check the inclinometer connector X23, CCM connector X142, and the in-line harness connector X111.

A. Disconnect connector X23. Turn the key start ON. Measure the voltage between connector X23 pin A,

A. Turn the key start OFF. Disconnect connector X142. Turn the key start ON. Check between connector
X23 pin C, circuit (032) (GE) and ground. If a voltage is indicated, repair or replace the harness as
required.
B. If the harness is okay, remove and replace the inclinometer. If the fault is still present, download the
correct level of software. If the fault re-occurs, remove and replace the CCM.

(A.30.A - C.20.E.13)
CS540 1260 > 1324
CS640 1260 > 1324

12160 1 02/07/2004
K.62.B / 130

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 131
vfil04cs0022h0a 1
12160 1 02/07/2004
K.62.B / 132

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

Line: 3400 - 3730
12160 1 02/07/2004
K.62.B / 133
vfil04cs0023h0a 2
12160 1 02/07/2004
K.62.B / 134
Index
CROP PROCESSING - K
CLEANING Primary cleaning - Special tools (K.62.B - D.20.A.40) 4

CS540, CS640, CS520, CS660
CLEANING Primary cleaning - Static description (K.62.B - C.30.A.20) 5
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Fan Deflector - Adjust (K.62.B.52.76 - F.45.A.01) 47
CS540, CS640, CS520, CS660
Fan Fan housing - Install (K.62.B.52.70 - F.10.A.15) 42
CS540, CS640, CS520, CS660
Fan Fan housing - Remove (K.62.B.52.70 - F.10.A.10) 36
CS540, CS640, CS520, CS660
Fan Shaft - Install (K.62.B.52.43 - F.10.A.15) 33
CS540, CS640, CS520, CS660
Fan Shaft - Remove (K.62.B.52.43 - F.10.A.10) 30
CS540, CS640, CS520, CS660
Fan variator Belt - Install (K.62.B.53.44 - F.10.A.15) 52
CS540, CS640, CS520, CS660
Fan variator Belt - Remove (K.62.B.53.44 - F.10.A.10) 49
CS540, CS640, CS520, CS660
Fan variator Driven disc - Assemble (K.62.B.53.51 - F.10.A.20) 57
CS540, CS640, CS520, CS660
Fan variator Driven disc - Disassemble (K.62.B.53.51 - F.10.A.25) 56
CS540, CS640, CS520, CS660
Fan variator Driven disc - Install (K.62.B.53.51 - F.10.A.15) 58
CS540, CS640, CS520, CS660
Fan variator Driven disc - Remove (K.62.B.53.51 - F.10.A.10) 55
CS540, CS640, CS520, CS660
Grain pan - Install (K.62.B.58 - F.10.A.15) 61
CS540, CS640, CS520, CS660
Grain pan - Remove (K.62.B.58 - F.10.A.10) 59
CS540, CS640, CS520, CS660
Sensing system Fan speed sensor - Open circuit (K.62.B.95.52 - G.30.B.50) 104
CS540, CS640, CS520, CS660
Sensing system Fan speed sensor - Short circuit to B+ (K.62.B.95.52 - G.30.B.54) 97
CS540, CS640, CS520, CS660
Sensing system Fan speed sensor - Short circuit to ground (K.62.B.95.52 - G.30.B.53) 90
CS540, CS640, CS520, CS660
Sensing system Lateral inclination sensor - Short circuit to B+ (K.62.B.95.50 - G.30.B.54) 130
CS540, CS640, CS520, CS660
Sensing system Lateral inclination sensor - Short circuit to ground (K.62.B.95.50 - G.30.B.53) 125
CS540, CS640, CS520, CS660
Sensing system Sieve grain loss sensor - Short circuit to B+ (K.62.B.95.55 - G.30.B.54) 118
CS540, CS640, CS520, CS660
12160 1 02/07/2004
K.62.B / 135
Sensing system Sieve grain loss sensor - Short circuit to ground (K.62.B.95.55 - G.30.B.53) 111
CS540, CS640, CS520, CS660
Shoe drive system - Exploded view (K.62.B.45 - C.10.A.20) 6
CS540, CS640, CS520, CS660
Shoe drive system - Sectional view (K.62.B.45 - C.10.A.30) 7
CS540, CS640, CS520, CS660
Shoe drive system Belt - Install (K.62.B.45.44 - F.10.A.15) 16
CS540, CS640, CS520, CS660
Shoe drive system Belt - Remove (K.62.B.45.44 - F.10.A.10) 15
CS540, CS640, CS520, CS660
Shoe drive system Shaft - Install (K.62.B.45.40 - F.10.A.15) 11
CS540, CS640, CS520, CS660
Shoe drive system Shaft - Remove (K.62.B.45.40 - F.10.A.10) 8
CS540, CS640, CS520, CS660
Upper shoe - Install (K.62.B.51 - F.10.A.15) 24
CS540, CS640, CS520, CS660
Upper shoe - Remove (K.62.B.51 - F.10.A.10) 17
CS540, CS640, CS520, CS660
Upper sieve levelling system - Adjust (K.62.B.64 - F.45.A.01) 62
CS540, CS640, CS520, CS660
Upper sieve levelling system Command - Short circuit to B+ (K.62.B.64.05 - G.30.B.54) 80
CS540, CS640, CS520, CS660
Upper sieve levelling system Command - Short circuit to ground (K.62.B.64.05 - G.30.B.53) 75
CS540, CS640, CS520, CS660
Upper sieve levelling system Motor - Short circuit to ground (K.62.B.64.58 - G.30.B.53) 85
CS540, CS640, CS520, CS660
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K.62.B / 136
CROP PROCESSING - K
CLEANING Tailings return system - 62.C
CS540
CS640
CS520
CS660
12161 1 02/07/2004
K.62.C / 1
Contents
CROP PROCESSING - K
FUNCTIONAL DATA
Cross auger
Cross auger - Exploded view (K.62.C.51 - C.10.A.20) 3
CS540, CS640, CS520, CS660
SERVICE
Cross auger
Cross auger - Remove (K.62.C.51 - F.10.A.10) 4
CS540, CS640, CS520, CS660
Cross auger - Install (K.62.C.51 - F.10.A.15) 8
CS540, CS640, CS520, CS660
Return auger
Return auger - Remove (K.62.C.53 - F.10.A.10) 12
CS540, CS640, CS520, CS660
Return auger - Install (K.62.C.53 - F.10.A.15) 14
CS540, CS640, CS520, CS660
Tailings elevator
Tailings elevator Chain - Remove (K.62.C.54.48 - F.10.A.10) 16
CS540, CS640, CS520, CS660
Tailings elevator Chain - Install (K.62.C.54.48 - F.10.A.15) 18
CS540, CS640, CS520, CS660
Tailings elevator - Remove (K.62.C.54 - F.10.A.10) 20
CS540, CS640, CS520, CS660
Tailings elevator - Install (K.62.C.54 - F.10.A.15) 24
CS540, CS640, CS520, CS660
DIAGNOSTIC
Sensing system
Sensing system Tailing speed sensor - Short circuit to ground (K.62.C.95.80 - G.30.B.53) 28
CS540, CS640, CS520, CS660
Sensing system Tailing speed sensor - Short circuit to B+ (K.62.C.95.80 - G.30.B.54) 35
CS540, CS640, CS520, CS660
Sensing system Tailing speed sensor - Open circuit (K.62.C.95.80 - G.30.B.50) 42
CS540, CS640, CS520, CS660
12161 1 02/07/2004
K.62.C / 2
CROP PROCESSING - CLEANING Tailings return system
Cross auger - Exploded view (K.62.C.51 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA6922A 1
Cross auger
1 Dowel pin 2 Sprocket

3 Cover 4 Bearing
5 Bolt 6 Shims
7 Washer 8 Bearing
9 Grease cover 10 Returns elevator
11 Returns cross auger 12 Sprocket
13 Retaining ring 14 Drive chain
12161 1 02/07/2004
K.62.C / 3
Cross auger - Remove (K.62.C.51 - F.10.A.10)

CS540, CS640, CS520, CS660
1. At the left-hand side, loosen the nut (2) of the idler

(1) and remove the cotter pins to open the coupler
links of the chain.
ZDA6052B 1
2. Remove the bolt (4) to open the cover (3).
ZDA6024B 2
3. Rotate the elevator chain until the coupler links are

accessible on the bottom sprocket.
4. Loosen the nut (3) to release the chain tension. If
not, loosen also the locknut (1).
ZDA6159B 3
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K.62.C / 4
5. To open the chain, remove the cotter pin (1), to

open the coupler links (2). To prevent from slipping
out of the returns elevator chain, fit a rope on both
ends of the chain.
ZDA7134A 4
6. Remove the dowel pin (1) of the sprocket (2).
ZDA6298A 5
7. Remove the two nuts (3) and remove the cover (4).
ZDA6300A 6
8. Remove the central bolt (5).

Remove two nuts (6).
ZDA6301A 7
12161 1 02/07/2004
K.62.C / 5
9. Remove the bearing flange (7), using a puller.
ZDA6302A 8
10. At the left-hand side, remove the retaining ring (1)

and the washers.
ZDA6303A 9
11. Remove the sprocket (2), using a puller.
ZDA6305A 10
12. Remove the key (3) and loosen the lock collar (4).
Loosen the three nuts (5).
ZDA6306A 11
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K.62.C / 6
13. Turn out the auger through the long sleeve hole at
the left-hand side.
At the right-hand side, remove the sprocket .
ZDA6950A 12
12161 1 02/07/2004
K.62.C / 7
Cross auger - Install (K.62.C.51 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the auger from the left-hand side by rotating

the auger until it is completely in it’s auger housing.
ZDA6950A 1
2. At the right-hand side, install sprocket (2) with the

dowel pin (1).
ZDA6298A_200 2
3. Install the left-hand side bearing (4) and tighten the

nuts (5). (Do not install the lock collar).
NOTE: Grease the spherical outer ring with NLGI-2 and
grease the inner ring of the bearing and the lock collar
with anti-corrosive grease.
ZDA6306C 3
12161 1 02/07/2004
K.62.C / 8
4. At the right-hand side, add shims (6) and the washer

(7) until distance “X" = 65 mm. (2-9/16 in)
Tighten central bolt (5).
ZDA6307A 4
5. Install the cover (4) and tighten the nuts (3).
ZDA6300A 5
6. Close the returns elevator chain and install the

cotter pins (1), to secure the coupler links (2).
ZDA7134A 6
7. Insert the cotter pins in the direction of travel.

(arrow)
ZDA7821A 7
12161 1 02/07/2004
K.62.C / 9
8. Adjust the tension of the chain with the nut (2) and
(3).
NOTE: The tension of the returns elevator chain is correct
when it is just possible to move a link laterally across the
lower sprocket by hand.
NOTE: After adjusting the returns elevator chain, check
the tension of the returns top auger drive chain (4).
ZDA6159C 8
9. Close the bottom of the returns elevator with the

cover (3) and secure it with the bolt (4).
ZDA6024B 9
10. At the left-hand side, install the lock collar (4) and
tighten the Allen screw.
NOTE: Grease the lock collar with anti-corrosive grease.
EDA6306B 10
11. Install the key (3).
12161 1 02/07/2004
K.62.C / 10
12. Install the sprocket, the shims and the retaining

ring (1).
ZDA6303A 11
13. Install the chain with the coupler links and secure it
with the cotter pins.
NOTE: Insert the cotter pins against the direction of travel.
(Refer to Tailings elevator Chain - Install (K.62.C.54.48
- F.10.A.15))
14. Adjust the chain with the idler (1) and tighten the
nut (2).
NOTE: The chain tension is correct when it is just possible
to move a link laterally across a sprocket by hand.
ZDA6052B 12
12161 1 02/07/2004
K.62.C / 11
Return auger - Remove (K.62.C.53 - F.10.A.10)

CS540, CS640, CS520, CS660
1. At the right-hand side, open the top cover (6).
ZDA6026A 1
2. Loosen the nut (2), to move the idler (1).

Remove the cotter pins to open the coupler links
of the drive chain.
ZDA5932A 2
3. Remove the retaining ring (3), the washers and the

sprocket (4).
Remove the key.
ZDA6982A 3
12161 1 02/07/2004
K.62.C / 12
4. Remove the four nuts (5).

Remove the bearing flange, using a puller.
ZDA6930A 4
5. At the left-hand side, remove the two bolts (1) to

remove the sensor support (2).
Remove the central bolt (3) and remove the sensor
plate (4).
ZDA6931A 5
6. Loosen the Allen screw and remove the lock collar

(5).
ZDA6983A 6
7. Push the shaft (6) out to the right-hand side, using

a hammer.
ZDA7311A 7
12161 1 02/07/2004
K.62.C / 13
Return auger - Install (K.62.C.53 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the auger into his tube by turning the auger

from the right-hand side.
ZDA7674A 1
2. Install the bearing housing and tighten the four bolts

(5).
ZDA6930A 2
3. At the left-hand side, install the lock collar (5) and

ZDA6983A 3
12161 1 02/07/2004
K.62.C / 14
4. Install the sensor plate (4) and tighten it with the

bolt (3).
Install the sensor support (2) and tighten it with the
two bolts (1).
ZDA6931A 4
5. At the right-hand side, install the key, the sprocket

(4), the washer and the retaining ring (3).
ZDA6982A_204 5
6. Install the returns top auger drive chain and tighten

it by moving the idler (1).
ZDA5932A 6
7. Close the top cover (6).
ZDA6026A 7
12161 1 02/07/2004
K.62.C / 15
Tailings elevator Chain - Remove (K.62.C.54.48 - F.10.A.10)

CS540, CS640, CS520, CS660

links of the chain.
ZDA6052B 1
2. Remove the bolt (4) to open the bottom cover (3)

of the returns elevator.
ZDA6024B 2

ZDA6159B 3
12161 1 02/07/2004
K.62.C / 16

open the coupler links (2).
ZDA7134A 4
6. Attach a rope or fit a new chain to the lower part of

the returns elevator chain.
ZDA6299A 5
7. Turn the old chain out.
ZDA6304A 6
12161 1 02/07/2004
K.62.C / 17
Tailings elevator Chain - Install (K.62.C.54.48 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Use the rope to pull in the old chain after rework.

Disconnect the rope from the old chain, if fit a new
chain.
NOTE: Check if the chain is installed in the right direction
as shown.
ZDA6304A_198 1
2. Close the chain with the coupler links (2).
ZDA7134A_199 2
3. Install the cotter pins (1), to secure the coupler links

(2).
NOTE: Insert the cotter pins in the direction of travel.
(arrow)
ZDA7821A 3
12161 1 02/07/2004
K.62.C / 18
4. Tighten the chain with the nut (2) and (3).

the tension of the returns top auger drive chain (4) and
adjust, if necessary.
ZDA6159C 4
5. Close the bottom of the returns elevator with the

cover (3) and secure it with the bolt (4).
ZDA6024B 5
6. At the left-hand side, install the chain with the

coupler links and secure it with the cotter pins.
7. Adjust the chain with the idler (1) and tighten the
nut (2).
NOTE: Then chain tension is correct when it is just
possible to move a link laterally across a sprocket by hand.
ZDA6052B 6
12161 1 02/07/2004
K.62.C / 19
Tailings elevator - Remove (K.62.C.54 - F.10.A.10)

CS540, CS640, CS520, CS660
1. At the left-hand side, Loosen the nut (2) of the idler

links of the chain.
ZDA6052B 1
2. At the right-hand side, remove the shielding by

removing the bolt (1) and the two bolts (2).
ZDA7247A 2
3. Move the idler (1) of the returns top auger drive

chain by loosening the nut (2).
of the drive chain.
ZDA5932A 3
12161 1 02/07/2004
K.62.C / 20
4. Remove the bolt (4) to open the cover (3).
ZDA6024B 4

ZDA6159B 5

out of the returns elevator chain, fit a rope on both
ends of the chain.
ZDA7134A 6
12161 1 02/07/2004
K.62.C / 21
8. Remove the dowel pin (1) of the sprocket (2).
ZDA6298A 7
9. Remove the two nuts (3) and remove the cover (4).
ZDA6300A 8
10. Remove the central bolt (5) and the washers.

ZDA6301A 9
ZDA6302A 10
12161 1 02/07/2004
K.62.C / 22
12. Remove the eight bolts (1) at the top of the returns
auger.
ZDA6982B 11
13. Remove the two bolts (3) at the bottom of the

returns cross auger.
ZDA7135A 12
14. Remove the two bolts (2) that connect the returns
elevator with the grain elevator.
ZDA6984A 13
15. Now is it possible to remove the returns elevator,

using an adequate lifting device.
12161 1 02/07/2004
K.62.C / 23
Tailings elevator - Install (K.62.C.54 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the returns elevator onto his place. Don’t

forget to install the sprocket on the returns bottom
cross auger.
Install the two bolts (2).
ZDA6984A 1
2. Install the eight bolts (1) at the top of the returns

elevator.
ZDA6982B 2
3. Install and tighten the two bolts (3) at the bottom

of the returns elevator.
ZDA7135A 3
12161 1 02/07/2004
K.62.C / 24
4. Install the bearing flange and tighten the two bolts

(6).
Install the washer and tighten the central bolt (5).
ZDA6301A_201 4
5. Install the grease cover (4) and tighten the two nuts
(3).
ZDA6300A 5
6. Install the sprocket (2) with the dowel pin (1).
ZDA6298A 6
7. Connect the returns elevator chain with the coupler

links (2) and secure them with the cotter pin (1).
(Refer to Tailings elevator Chain - Install (K.62.C.54.48
- F.10.A.15))
ZDA7134A 7
12161 1 02/07/2004
K.62.C / 25
8. Adjust the chain tension with the nuts (2) and (3).
the tension of the returns top auger drive chain (4).
ZDA6159C 8
9. Install the returns top auger drive chain and adjust it

by moving idler (1).
ZDA5932A_202 9
10. Install the cover (3) at the bottom of the returns

elevator and secure it with the bolt (4).
ZDA6024B_203 10
11. Install the shielding and tighten the bolts (1) and (2).
ZDA7247A 11
12161 1 02/07/2004
K.62.C / 26
12. At the left-hand side, close the chain with the

coupler links and install the cotter pins.
Adjust the chain by moving the idler (1) and tighten
it with nut (2).
ZDA6052B 12
12161 1 02/07/2004
K.62.C / 27
Sensing system Tailing speed sensor - Short circuit to ground

(K.62.C.95.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E113 - RETURN ELEVATOR (B12) SENSOR SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty return elevator sensor
Solution:
1. Check the return elevator sensor connector X33, CCM connector X141, and the in-line harness connector X26.

(ZW) and ground. If a short to ground is indicated, remove and replace the return elevator sensor.


4. Check the return elevator sensor.
A. Connect connector X141. Remove the return elevator sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect return elevator sensor to connector X32. Turn the key start
the return elevator sensor.

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12161 1 02/07/2004
K.62.C / 28

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 29
55_a3cs016 1
12161 1 02/07/2004
K.62.C / 30

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 31
vfil04cs0026h0a 2
12161 1 02/07/2004
K.62.C / 32

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 33
vfil04cs0027h0a 3
12161 1 02/07/2004
K.62.C / 34
Sensing system Tailing speed sensor - Short circuit to B+

(K.62.C.95.80 - G.30.B.54)
CS540, CS640, CS520, CS660
E114 - RETURN ELEVATOR (B12) SENSOR SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the return elevator sensor connector X33 and the in-line harness connector X26.


(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12161 1 02/07/2004
K.62.C / 35

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 36
55_a3cs016 1
12161 1 02/07/2004
K.62.C / 37

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 38
vfil04cs0026h0a 2
12161 1 02/07/2004
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CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 40
vfil04cs0027h0a 3
12161 1 02/07/2004
K.62.C / 41
Sensing system Tailing speed sensor - Open circuit (K.62.C.95.80 -

G.30.B.50)
CS540, CS640, CS520, CS660
E115 - RETURN ELEVATOR (B12) SENSOR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty return elevator sensor
Solution:
1. Check the return elevator sensor connector X33, CCM connector X141, and the in-line harness connector X26.



A. Turn the key start OFF. Remove the return elevator sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect return elevator sensor to connector X32. Turn the key start
the return elevator sensor.
the CCM.
12161 1 02/07/2004
K.62.C / 42

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 43
55_a3cs016 1
12161 1 02/07/2004
K.62.C / 44

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 45
vfil04cs0026h0a 2
12161 1 02/07/2004
K.62.C / 46

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12161 1 02/07/2004
K.62.C / 47
vfil04cs0027h0a 3
12161 1 02/07/2004
K.62.C / 48
Index
CROP PROCESSING - K
Cross auger - Exploded view (K.62.C.51 - C.10.A.20) 3

CS540, CS640, CS520, CS660
Cross auger - Install (K.62.C.51 - F.10.A.15) 8
CS540, CS640, CS520, CS660
Cross auger - Remove (K.62.C.51 - F.10.A.10) 4
CS540, CS640, CS520, CS660
Return auger - Install (K.62.C.53 - F.10.A.15) 14
CS540, CS640, CS520, CS660
Return auger - Remove (K.62.C.53 - F.10.A.10) 12
CS540, CS640, CS520, CS660
Sensing system Tailing speed sensor - Open circuit (K.62.C.95.80 - G.30.B.50) 42
CS540, CS640, CS520, CS660
Sensing system Tailing speed sensor - Short circuit to B+ (K.62.C.95.80 - G.30.B.54) 35
CS540, CS640, CS520, CS660
Sensing system Tailing speed sensor - Short circuit to ground (K.62.C.95.80 - G.30.B.53) 28
CS540, CS640, CS520, CS660
Tailings elevator - Install (K.62.C.54 - F.10.A.15) 24
CS540, CS640, CS520, CS660
Tailings elevator - Remove (K.62.C.54 - F.10.A.10) 20
CS540, CS640, CS520, CS660
Tailings elevator Chain - Install (K.62.C.54.48 - F.10.A.15) 18
CS540, CS640, CS520, CS660
Tailings elevator Chain - Remove (K.62.C.54.48 - F.10.A.10) 16
CS540, CS640, CS520, CS660
12161 1 02/07/2004
K.62.C / 49
12161 1 02/07/2004
K.62.C / 50
CROP PROCESSING - K
STORING AND HANDLING Grain storing - 60.B
CS540
CS640
CS520
CS660
12162 1 02/07/2004
K.60.B / 1
Contents
CROP PROCESSING - K
FUNCTIONAL DATA
Clean grain cross auger

Clean grain cross auger - Exploded view (K.60.B.51 - C.10.A.20) 3
CS540, CS640, CS520, CS660
SERVICE
Clean grain cross auger

Clean grain cross auger - Remove (K.60.B.51 - F.10.A.10) 5
CS540, CS640, CS520, CS660
Clean grain cross auger - Install (K.60.B.51 - F.10.A.15) 9
CS540, CS640, CS520, CS660
Grain elevator
Grain elevator Chain - Remove (K.60.B.52.48 - F.10.A.10) 13
CS540, CS640, CS520, CS660
Grain elevator Chain - Install (K.60.B.52.48 - F.10.A.15) 15
CS540, CS640, CS520, CS660
Grain elevator - Remove (K.60.B.52 - F.10.A.10) 17
CS540, CS640, CS520, CS660
Grain elevator - Install (K.60.B.52 - F.10.A.15) 20
CS540, CS640, CS520, CS660
Tank delivery auger

Tank delivery auger - Remove (K.60.B.53 - F.10.A.10) 23
CS540, CS640, CS520, CS660
Tank delivery auger - Install (K.60.B.53 - F.10.A.15) 25
CS540, CS640, CS520, CS660
12162 1 02/07/2004
K.60.B / 2
CROP PROCESSING - STORING AND HANDLING Grain storing
Clean grain cross auger - Exploded view (K.60.B.51 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA6958A 1
Right-hand side
1 Sprocket 2 Dowel pin

3 Bearing 4 Bolt
5 Central bolt 6 Grease cover
7 Grain elevator 8 Bolt
9 Key 10 Seal plate
12162 1 02/07/2004
K.60.B / 3
ZDA6957A 2
Left-hand side
1 Retaining ring 2 Pulley

3 Sprocket 4 Key
5 Washers 6 Bearing
7 Bearing flange 8 Plate
12162 1 02/07/2004
K.60.B / 4
Clean grain cross auger - Remove (K.60.B.51 - F.10.A.10)

CS540, CS640, CS520, CS660

(1).
of the drive chain.
ZDA6052B_208 1
2. Loosen the nut (1) and remove the drive belt (2)
from the pulley.
ZDA6723A_209 2
3. At the right-hand side, remove the bolt (3).

Open the bottom cover (2) of the grain elevator.
ZDA6038A 3

12162 1 02/07/2004
K.60.B / 5
5. Loosen the nut (2) and (3) to release the grain

elevator chain. If not, loosen also the nut (1).
ZDA6148B_210 4
5
out of the grain elevator chain, fit a rope on both
ends of the chain.
7. Remove the dowel pin (1) out of the sprocket (2).
ZDA6946A 6
8. Remove the two nuts (3) and remove the grease

cover (4).
ZDA6949A 7
12162 1 02/07/2004
K.60.B / 6
9. Remove the central bolt (5) and the washer.

ZDA6960A 8
ZDA6961A 9
11. At the left-hand side, remove the retaining ring (1).

Remove the V-pulley (2) by using a puller.
ZDA6723B 10
12. Remove the key (3) and the washers.

(4).
ZDA6953A 11
12162 1 02/07/2004
K.60.B / 7
13. Loosen the three nuts (5) of the bearing flange.
ZDA6952A 12
14. Remove the bearing (6) with the flanges (7).

Remove the plate (8).
ZDA6954A 13
15. Turn out the auger through the long sleeve hole at
the left-hand side.
At the right-hand side, remove the sprocket.
ZDA6951A 14
12162 1 02/07/2004
K.60.B / 8
Clean grain cross auger - Install (K.60.B.51 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the auger from the left-hand side by rotating

the auger until it is completely in it’s auger housing.
ZDA6951A 1
2. At the left-hand side, install the plate, the bearing

with the flanges and tighten the nuts (5).
NOTE: Grease the spherical outer ring with grease
NLGI-2 and grease the inner ring of the bearing with
anti-corrosive grease.
ZDA6952A 2
3. Install the sprocket (1) with the dowel pin (2).

(right-hand side)
NOTE: Check if the key (3) is installed.
ZDA6956A 3
4. Install the right-hand side bearing (4) and tighten

the two nuts (5).
grease the inner ring of the bearing with anti-corrosive
grease.
5. Install the shims, the washer and tighten the central
bolt (6).
NOTE: Check if the distance “X" is between 96.5 - 98.5
mm. (3-13/16 - 3-7/8 in)
12162 1 02/07/2004
K.60.B / 9
6. Install the cover (7) and tighten the other two nuts
(5).
7. Grease the bearing.
8. At the left-hand side, install and tighten the lock
collar (4).
Install the washers and the key (3).
ZDA6953A_211 4
ZDA6723B 5
10. Install the retaining ring (1).(see fig.5)

NOTE: Check if the distance “X" = 90 mm (3-1/2 in) or
in line is with the pulley (3).
ZDA6959A 6
12162 1 02/07/2004
K.60.B / 10
11. Close the grain elevator chain, with the coupler links
(2).
Install the cotter pins (1) to secure the coupler links
(2).
ZDA7133A 7
12. Adjust the grain elevator chain tension with the nuts
(2) and (3).
NOTE: The tension is correct when the chain can be
moved axial across the lower sprocket by hand.
ZDA6148A_212 8
13. After adjusting the grain elevator chain, check the

tension of the grain tank filling auger drive chain (4).
14. Close the bottom cover (2) of the grain elevator.
Secure the cover with the bolt (3).
ZDA6038A 9
12162 1 02/07/2004
K.60.B / 11
15. Install the drive belt (2) and adjust the belt with
the nut (1) as described in the CS Operator’s
MAINTENANCE"; paragraph headed: “Drive belts
and Chains".
ZDA6723A 10
16. Install and close the drive chain with the coupler
links and install the cotter pins.
Adjust the idler (2) and tighten it with the nut (1).
ZDA6052B_208 11
12162 1 02/07/2004
K.60.B / 12
Grain elevator Chain - Remove (K.60.B.52.48 - F.10.A.10)

CS540, CS640, CS520, CS660

Open the cover (2).
ZDA6038A 1
2. Loosen the nut (1) or push down the idler and

remove the belt (2) from the pulley.
ZDA6723A 2
3. Rotate the elevator chain (1) until the coupler links

are accessible on the bottom sprocket.
ZDA6055A 3
12162 1 02/07/2004
K.60.B / 13
4. Loosen the nut (2) and (3) to release the grain

elevator chain. If not, loosen also the nut (1).
ZDA6148B 4

open the coupler links (2).
ZDA7133A 5
6. Attach a rope or fit a new chain to one side of the

grain elevator chain.
Turn the old chain out.
ZDA7086A 6
12162 1 02/07/2004
K.60.B / 14
Grain elevator Chain - Install (K.60.B.52.48 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Use the rope to pull in the old chain after rework.

Disconnect the rope of the old chain, if fit a new
chain.
IMPORTANT: Check if the chain is installed in the right
direction.
ZDA7086A_205 1
2. Close the chain with the coupler links (2).

Install the cotter pins (1), to secure the coupler links.
ZDA7133A_206 2
3. The chain tension can be adjusted with the nuts

(2) and (3).
NOTE: The tension is correct when the chain can be
moved axial across the lower sprocket by hand.
ZDA6148A 3
4. After adjusting the grain elevator chain, check the

tension of the grain tank filling auger drive chain (4).
12162 1 02/07/2004
K.60.B / 15
5. Close the bottom of the grain elevator with the cover

(2).
Install the bolt (3).
ZDA6038A_207 4
12162 1 02/07/2004
K.60.B / 16
Grain elevator - Remove (K.60.B.52 - F.10.A.10)

CS540, CS640, CS520, CS660
Prior operation: Refer to Tailings elevator - Remove (K.62.C.54 - F.10.A.10).
1. Loosen the bolt to remove the support (1) from the

grain elevator.
ZDA7536A 1
2. Lift-up the combine at the rear, by using an

adequate lifting device.
Remove the right-hand side steering wheel.
ZDA7535A 2
3. Refer to Grain elevator Chain - Remove

(K.60.B.52.48 - F.10.A.10).
4. Remove the two nuts (3) and remove the grease
cover (4).
ZDA6949A_213 3
12162 1 02/07/2004
K.60.B / 17
5. Remove the central bolt (5) and the washers.

ZDA6960A_214 4
ZDA6961A_215 5
7. If a rotary separator is installed, remove the two

bolts (1) and remove the handle (2).
Release the rotary separator drive belt and remove
the bolt (3).
ZDA7252A 6
8. Enter the grain tank and loosen the bolts (1) to

disconnect the lower part from the upper part of the
grain elevator.
ZDA7137A 7
12162 1 02/07/2004
K.60.B / 18
9. Remove the seal plate by loosening all the bolts (1).
ZDA6962A 8
10. Hang-up the grain elevator by using an adequate

lifting device.
Loosen the nuts (1) on the top of the grain elevator
on both sides.
ZDA6947A 9
11. Loosen the two bolts (2) on the bottom of the grain
elevator.
ZDA6948A 10
12. Remove the grain elevator completely, using an

ZDA6955A 11
12162 1 02/07/2004
K.60.B / 19
Grain elevator - Install (K.60.B.52 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the grain elevator onto his place, using an

ZDA6955A_216 1
2. Install the two bolts (2) at the bottom of the grain

elevator tube.
ZDA6948A 2
3. Install and tighten the two bolts (1) on the top of

the grain elevator.
Tighten the bolts (2). (see fig.2)
ZDA6947A 3
12162 1 02/07/2004
K.60.B / 20
4. Attach the lower part of the grain elevator to the

upper part by installing the bolts (1).
ZDA7137A_217 4
5. Install the right-hand side bearing (4) and tighten

the two nuts (5).
grease the inner ring of the bearing with anti-corrosive
grease.
ZDA6956A 5
6. Install the shims, the washer and tighten the central

bolt (6).
NOTE: Check that the dimension “X" is between 96.5 -
98.5 mm. (3-13/16 - 3-7/8 in)
7. Install the cover (7) and tighten the other two nuts
(5).
8. Grease the bearing.
9. Install the seal plate and tighten the bolts (1).
ZDA6962A 6
12162 1 02/07/2004
K.60.B / 21
10. Install the grain elevator chain: Refer to Grain

elevator Chain - Install (K.60.B.52.48 - F.10.A.15).
Install the support (1).
ZDA7536A_218 7
11. If a rotary separator is installed, install the handle

(2) and tighten it with the two bolts (1).
Install the support with the bolt (3).
Tighten the rotary separator drive belt.
ZDA7252A 8
12. Install the right-hand steering wheel.

Remove the wooden blocks of the steering axle.
ZDA7535A 9
Next operation: Refer to Tailings elevator - Install (K.62.C.54 - F.10.A.15)
12162 1 02/07/2004
K.60.B / 22
Tank delivery auger - Remove (K.60.B.53 - F.10.A.10)

CS540, CS640, CS520, CS660
1. At the right-hand side, loosen the nut (2) to release

the sprocket (1).
Remove the unloading drive chain.
ZDA6078B_227 1

Remove sprocket (4) with the hub, using a puller.
ZDA6928A 2
3. Remove the two keys (5).

Loosen the three bolts (6) of the bearing housing (7).
Remove the bearing housing, using a puller.
ZDA6964A 3
12162 1 02/07/2004
K.60.B / 23
4. Inside the grain tank:

Enter the grain tank and loosen the four nuts to
remove the cover (1).
ZDA6963A 4
5. Remove the four bolts and remove the cover (2).
ZDA6131C 5
6. Remove the roll pin (3) and the universal yoke (4).
Remove the two bolts (5) and the two bolts (6) to
remove support (7).
ZDA7315A 6
7. Take out the grain tank bottom auger (8).
ZDA7316A 7
12162 1 02/07/2004
K.60.B / 24
Tank delivery auger - Install (K.60.B.53 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the auger in the grain tank.

Install the support (7) and tighten the bolts (5).
Install the bearing housing and tighten the two bolts
(6).
NOTE: Grease the seals of the bearing with grease
NLGI-2. Grease the inner ring of the bearing with
"molybdeen sulphate" grease.
ZDA7488A 1
2. At the right hand side, install the bearing housing (7)

with the bearing and tighten the three bolts (6).
ZDA6964A_228 2
3. Install the sprocket (4) and the retaining ring (3).
ZDA6928A_229 3
12162 1 02/07/2004
K.60.B / 25
4. Install the unloading drive chain and adjust it

with the sprocket (1). Refer to the CS Operator’s
manual; "SECTION 4 - LUBRICATION AND
MAINTENANCE", paragraph headed: "Drive belts
and chains".
ZDA6078B 4
5. Inside the grain tank, install the lock collar and

ZDA7315B 5
6. Install the yoke (4) and the two roll pins (3). (see
also fig.5)
ZDA7844C 6
7. Install the cover (2) and tighten the four bolts.
ZDA6131C_230 7
12162 1 02/07/2004
K.60.B / 26
8. Install the cover (1) and tighten the four nuts.
ZDA6963A 8
12162 1 02/07/2004
K.60.B / 27
Index
CROP PROCESSING - K
Clean grain cross auger - Exploded view (K.60.B.51 - C.10.A.20) 3

CS540, CS640, CS520, CS660
Clean grain cross auger - Install (K.60.B.51 - F.10.A.15) 9
CS540, CS640, CS520, CS660
Clean grain cross auger - Remove (K.60.B.51 - F.10.A.10) 5
CS540, CS640, CS520, CS660
Grain elevator - Install (K.60.B.52 - F.10.A.15) 20
CS540, CS640, CS520, CS660
Grain elevator - Remove (K.60.B.52 - F.10.A.10) 17
CS540, CS640, CS520, CS660
Grain elevator Chain - Install (K.60.B.52.48 - F.10.A.15) 15
CS540, CS640, CS520, CS660
Grain elevator Chain - Remove (K.60.B.52.48 - F.10.A.10) 13
CS540, CS640, CS520, CS660
Tank delivery auger - Install (K.60.B.53 - F.10.A.15) 25
CS540, CS640, CS520, CS660
Tank delivery auger - Remove (K.60.B.53 - F.10.A.10) 23
CS540, CS640, CS520, CS660
12162 1 02/07/2004
K.60.B / 28
CROP PROCESSING - K
UNLOADING Grain unloading - 72.B
CS540
CS640
CS520
CS660
12163 1 02/07/2004
K.72.B / 1
Contents
CROP PROCESSING - K
FUNCTIONAL DATA
Cylinder
Cylinder - Sectional view (K.72.B.26 - C.10.A.30) 3
CS540, CS640, CS520, CS660
Drive system
Drive system - Exploded view (K.72.B.40 - C.10.A.20) 4
CS540, CS640, CS520, CS660
SERVICE
Cylinder
Cylinder - Service instruction (K.72.B.26 - F.10.A.05) 5
CS540, CS640, CS520, CS660
Drive system
Drive system Shaft - Remove (K.72.B.40.40 - F.10.A.10) 7
CS540, CS640, CS520, CS660
Drive system Shaft - Install (K.72.B.40.40 - F.10.A.15) 9
CS540, CS640, CS520, CS660
Drive system Belt - Remove (K.72.B.40.44 - F.10.A.10) 13
CS540, CS640, CS520, CS660
Drive system Belt - Install (K.72.B.40.44 - F.10.A.15) 15
CS540, CS640, CS520, CS660
Unloading tube
Unloading tube - Remove (K.72.B.71 - F.10.A.10) 17
CS540, CS640, CS520, CS660
Unloading tube - Install (K.72.B.71 - F.10.A.15) 19
CS540, CS640, CS520, CS660
12163 1 02/07/2004
K.72.B / 2
CROP PROCESSING - UNLOADING Grain unloading
Cylinder - Sectional view (K.72.B.26 - C.10.A.30)

CS540, CS640, CS520, CS660
CAUTION
ZDF0433A 1
UNLOADING TUBE CYLINDER

3 Seal 4 Seal
5 Guide ring 6 Seal
7 Seal 8 Piston guide ring
9 Scraper ring 10 Piston guide ring
11 Washer 12 Cylinder head
13 Bolt (torque 169-205 Nm)
12163 1 02/07/2004
K.72.B / 3
Drive system - Exploded view (K.72.B.40 - C.10.A.20)

CS540, CS640, CS520, CS660
ZDA6925A 1
1Bolts 2Front belt guide

3Unloading drive belt 4Nut
5Bolt 6Pulley
7Key 8Nut
9Bearing 10Rear Belt guide
12163 1 02/07/2004
K.72.B / 4
Cylinder - Service instruction (K.72.B.26 - F.10.A.05)

CS540, CS640, CS520, CS660
"Unloading tube cylinder with a detachable cylinder head"
Proceed as follows:
1. Loosen the cylinder head (1) by turning the head

clock wise, using a punch mark and a hammer.
ZDF0729A 1
ZDF0728A 2

ZDF0734A 3
12163 1 02/07/2004
K.72.B / 5
4. Clean and oil the piston rod (2), the cylinder sleeve
(4) and the seals and reassemble them.
ZDF0734A 4
5. Slide the pre-assembled piston rod (2) in the

cylinder housing.
Turn the cylinder head (1) counter-clockwise onto
the cylinder housing.
ZDF0728A_72 5
6. Tighten the cylinder head, using a punch mark and

a hammer.
12163 1 02/07/2004
K.72.B / 6
Drive system Shaft - Remove (K.72.B.40.40 - F.10.A.10)

CS540, CS640, CS520, CS660
1. At the left-hand side, loosen the bolts (1) to remove

the belt guide (2).
Remove the belt (3) from the pulley.
ZDA6927A_224 1
2. Loosen the nut (4) and the bolt (5).

Remove the V-pulley (6), using a puller.
ZDA6924A 2

Loosen the three bolts (8) of the bearing flange.
Remove the bearing flange.
ZDA6929A 3
12163 1 02/07/2004
K.72.B / 7
4. At the right-hand side, loosen the nut (2) to release

the sprocket (1).
Remove the unloading drive chain.
ZDA6078B 4
5. Loosen the nut (3) and the bolt (4).

Remove the sprocket (5), using a puller.
ZDA6923A 5

(7).
Remove the two bolts (8) of the bearing housing (9).
ZDA6966A 6
7. Slide the intermediate shaft (1) out to the right-hand

side.
Remove the bearing from the shaft, if necessary.
ZDA7563A 7
12163 1 02/07/2004
K.72.B / 8
Drive system Shaft - Install (K.72.B.40.40 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the shaft (1) onto his place.

At the right-hand side, install the bearing (2) onto
the shaft.
IMPORTANT: Grease the inner ring of bearing with
"anti-corrosive" grease.
ZDA7564A 1
2. Install the bearing in the bearing housing (9).

Install and tighten the two nuts (8).
ZDA7119A 2
3. At the left-hand side, install the bearing with the

flange and tighten the three bolts (8).
ZDA6929A 3
12163 1 02/07/2004
K.72.B / 9
4. Install and adjust the pulley (6) of the intermediate

shaft with dimension "X" = 175 mm (6-7/8 in), this
in line with the pulley (1).
ZDA6934A 4
5. After adjusting tighten the bolt (5) of the pulley (6).

ZDA6924A_225 5
6. Install the belt (3).

Install the belt guide (2) and install the bolts (1).
ZDA6927A_224 6
7. From series 1320: Engage the unloading

mechanism (without starting the engine) by turning
the button (1) on the pneumatic valve a quarter
clock-wise.
ZDA6611B 7
12163 1 02/07/2004
K.72.B / 10

the screw (2) on the pneumatic valve a quarter
clock-wise.
ZEIL04CS0055A0B 8
9. Adjust the belt guide with dimension "X" between 5

- 7 mm (3/16 - 1/4 in) by engaging the unloading
mechanism manually.
Tighten the nuts (1). (fig.6)
NOTE: After adjusting, disengage the unloading
mechanism by turning the button (or screw) on the
pneumatic valve a quarter counter-clockwise.
ZDA6933A_226 9
10. At the right-hand side, install the lock collar (7) and
ZDA6366B 10
11. Install the sprocket (5).
ZDA6923A 11
12163 1 02/07/2004
K.72.B / 11
12. Adjust the sprocket (5) of the intermediate shaft in

line with the sprocket (1) of the unloading bottom
auger.
After adjusting install the bolt (4) and the nut
(3).(fig.11)
ZDA6935A 12
13. Install the unloading drive chain.

Adjust the chain tension with the sprocket (1) and
tighten the nut (2).
ZDA6078B 13
12163 1 02/07/2004
K.72.B / 12
Drive system Belt - Remove (K.72.B.40.44 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Disconnect the pneumatic hose at (1).
ZDA7084A 1
2. Loosen the nut (1) to release the main drive belt.
ZDA5937B_222 2
3. Remove the main drive belt (2) completely.
ZDA6257B_223 3
12163 1 02/07/2004
K.72.B / 13
4. If a chopper is installed, loosen the nut (1) to release

the chopper front drive belt and remove the belt
completely.
ZDA6054B 4
5. Remove the front belt guide (2) of the unloading

drive belt (3) completely by removing the bolts (1).
ZDA6927A 5
6. Remove the nuts (3) of the rear belt guide (4).
ZDA6932A 6
7. Remove the unloading drive belt.
ZDA6941A 7
12163 1 02/07/2004
K.72.B / 14
Drive system Belt - Install (K.72.B.40.44 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Install the new belt.
ZDA6941A 1

the button (1) of the pneumatic valve clock-wise,
that is located at the left-hand side above the battery
key.
ZDA6611B 2
3. From series 1376: The combine is equipped with a

pneumatic valve as shown: Press onto the screw
(2) and turn it 1/4 clockwise, using a screw driver.
ZEIL04CS0055A0B 3
12163 1 02/07/2004
K.72.B / 15
4. Install and adjust the two belt guides with dimension

"X" between 5 - 7 mm. (3/16 - 1/4 in)
Tighten the nuts of the both belt guides.
ZDA6933A 4
5. Release the unloading belt tensioner by turning the

button (1) of the pneumatic valve.
(If the combine is equipped with a valve as
shown in figure (4), turn the screw a quarter
counter-clockwise)
ZDA6611B 5
6. Install the chopper front drive belt, and adjust as

described in the CS Operators manual: SECTION 4
- LUBRICATION AND MAINTENANCE, paragraph;
“Drive belts and chains".
7. Install the main drive belt, and adjust as described
in the CS Operators manual: SECTION 4 -
LUBRICATION AND MAINTENANCE, paragraph;
“Drive belts and chains".
8. Connect the pneumatic hose at (1).
ZDA7084A 6
12163 1 02/07/2004
K.72.B / 16
Unloading tube - Remove (K.72.B.71 - F.10.A.10)

CS540, CS640, CS520, CS660
1. Remove the roll pin (1).

Remove the two bolts (2).
Support the unloading tube with adequate lifting
tools.
WARNING
Z029 - Use a minimum of two lifting slings, separated
with a minimum 2.4 m (8′) wide spreader bar to keep
the slings in position. Failure to do so may result
in the auger becoming unbalanced and dropping
suddenly.
ZDA6936A 1
2. Remove the fifteen bolts (3) to disconnect the

unloading tube with the auger from the elbow.
ZDA6939A 2
3. Loosen the three nuts (4) to remove the end cap (5).
ZDA6939A_219 3
12163 1 02/07/2004
K.72.B / 17
4. Remove the roll pin (6), the shims (7) and the lock
collar (8).
ZDA6940A 4
5. Remove the bearing by loosening the three nuts (9).
ZDA7068A 5
6. Remove the auger out of his tube.
ZDA7067A 6
12163 1 02/07/2004
K.72.B / 18
Unloading tube - Install (K.72.B.71 - F.10.A.15)

CS540, CS640, CS520, CS660
1. Bring the auger into his tube.

Install the bearing with the flanges and tighten the
three nuts (9).
ZDA7068A_220 1
2. Align the square hole in the flange of the unloading

tube with the square hole of the elbow (as shown).
ZDA7840A 2
3. Install and tighten the fifteen bolts (3).
ZDA6939A 3
12163 1 02/07/2004
K.72.B / 19
4. Install the bearing support and tighten it with the

two bolts (2).
IMPORTANT: When installing the auger, make sure that
the position of it with respect to the position of the yoke
is correct (i.e. the auger flighting has to continue from
yoke to auger).
ZDA6936A_221 4
5. Install the two roll pins (1) as shown.
ZDA7844B 5
6. Before tighten the lock collar (1), (fig.6), check if

dimension “X" is between 56 - 57 mm. (2-13/64
- 2-1/4 in)
NOTE: If the half shaft (2) of the yoke touches tube (3) of
the yoke internally, reduce dimension “X" by adding the
shims (7), (fig.7) until the clearance “Y" between both is
maximum 2 mm. (5/64 in)
12163 1 02/07/2004
K.72.B / 20
ZDA6938A 6
7. After adjusting, install the lock collar (8) and tighten

the Allen screw.
Install the shims (7) as described above and install
the roll pin (6).
ZDA6940A 7
8. Install the end cap (5) and tighten it with the nuts (4).
ZDA6939A_219 8
12163 1 02/07/2004
K.72.B / 21
Index
CROP PROCESSING - K
Cylinder - Sectional view (K.72.B.26 - C.10.A.30) 3

CS540, CS640, CS520, CS660
Cylinder - Service instruction (K.72.B.26 - F.10.A.05) 5
CS540, CS640, CS520, CS660
Drive system - Exploded view (K.72.B.40 - C.10.A.20) 4
CS540, CS640, CS520, CS660
Drive system Belt - Install (K.72.B.40.44 - F.10.A.15) 15
CS540, CS640, CS520, CS660
Drive system Belt - Remove (K.72.B.40.44 - F.10.A.10) 13
CS540, CS640, CS520, CS660
Drive system Shaft - Install (K.72.B.40.40 - F.10.A.15) 9
CS540, CS640, CS520, CS660
Drive system Shaft - Remove (K.72.B.40.40 - F.10.A.10) 7
CS540, CS640, CS520, CS660
Unloading tube - Install (K.72.B.71 - F.10.A.15) 19
CS540, CS640, CS520, CS660
Unloading tube - Remove (K.72.B.71 - F.10.A.10) 17
CS540, CS640, CS520, CS660
12163 1 02/07/2004
K.72.B / 22
CROP PROCESSING - K
RESIDUE HANDLING Straw chopper - 64.C
CS540
CS640
CS520
CS660
12164 1 02/07/2004
K.64.C / 1
Contents
CROP PROCESSING - K
DIAGNOSTIC
Sensing system
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Sensing system Swath plate position sensor - Short circuit to ground (K.64.C.95.82 24
- G.30.B.53)
CS540, CS640, CS520, CS660
Sensing system Swath plate position sensor - Short circuit to B+ (K.64.C.95.82 - 31
G.30.B.54)
CS540, CS640, CS520, CS660
Sensing system Swath plate position sensor - Open circuit (K.64.C.95.82 - G.30.B.50) 38
CS540, CS640, CS520, CS660
12164 1 02/07/2004
K.64.C / 2
CROP PROCESSING - RESIDUE HANDLING Straw chopper

(K.64.C.95.80 - G.30.B.53)
CS540, CS640, CS520, CS660
E116 - STRAW CHOPPER (B10) SENSOR SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty straw chopper sensor
Solution:
1. Check the straw chopper sensor connector X30, CCM connector X141, and the in-line harness connector X98.

(ZW) and ground. If a short to ground is indicated, remove and replace the straw chopper sensor.


4. Check the straw chopper sensor.
A. Connect connector X141. Remove the straw chopper sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect straw chopper sensor to connector X32. Turn the key start ON.
chopper sensor.

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12164 1 02/07/2004
K.64.C / 3

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 4
55_a3cs016 1
12164 1 02/07/2004
K.64.C / 5

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 6
vfil04cs0026h0a 2
12164 1 02/07/2004
K.64.C / 7

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 8
vfil04cs0027h0a 3
12164 1 02/07/2004
K.64.C / 9
Sensing system Speed sensor - Short circuit to B+ (K.64.C.95.80 -

G.30.B.54)
CS540, CS640, CS520, CS660
E117 - STRAW CHOPPER (B10) SENSOR SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the straw chopper sensor connector X30 and the in-line harness connector X98.


(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12164 1 02/07/2004
K.64.C / 10

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 11
55_a3cs016 1
12164 1 02/07/2004
K.64.C / 12

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 13
vfil04cs0026h0a 2
12164 1 02/07/2004
K.64.C / 14

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 15
vfil04cs0027h0a 3
12164 1 02/07/2004
K.64.C / 16
Sensing system Speed sensor - Open circuit (K.64.C.95.80 -

G.30.B.50)
CS540, CS640, CS520, CS660
E118 - STRAW CHOPPER (B10) SENSOR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty straw chopper sensor
Solution:
1. Check the straw chopper sensor connector X30, CCM connector X141, and the in-line harness connector X98.



A. Turn the key start OFF. Remove the straw chopper sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect straw chopper sensor to connector X32. Turn the key start ON.
chopper sensor.
the CCM.
12164 1 02/07/2004
K.64.C / 17

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 18
55_a3cs016 1
12164 1 02/07/2004
K.64.C / 19

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 20
vfil04cs0026h0a 2
12164 1 02/07/2004
K.64.C / 21

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 22
vfil04cs0027h0a 3
12164 1 02/07/2004
K.64.C / 23
Sensing system Swath plate position sensor - Short circuit to

ground (K.64.C.95.82 - G.30.B.53)
CS540, CS640, CS520, CS660
E122 - SWATH PLATE POSITION (B26) SENSOR SHORT TO GROUND

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty swath plate position sensor
Solution:
1. Check the swath plate position sensor connector X97, CCM connector X142, and the in-line harness
connectors X98 and X5.

(ZW) and ground. If a short to ground is indicated, remove and replace the swath plate position sensor.


4. Check the swath plate position sensor.
A. Connect connector X142. Remove the swath plate position sensor. Disconnect the rotary separator
sensor connector X32. Connect the suspect swath plate position sensor to connector X32. Turn the
key start ON. Check if the error code E119 is now also displayed. If error code E119 is displayed,
replace the swath plate position sensor.

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260
12164 1 02/07/2004
K.64.C / 24

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 25
55_a3cs016 1
12164 1 02/07/2004
K.64.C / 26

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 27
vfil04cs0026h0a 2
12164 1 02/07/2004
K.64.C / 28

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 29
vfil04cs0027h0a 3
12164 1 02/07/2004
K.64.C / 30
Sensing system Swath plate position sensor - Short circuit to B+

(K.64.C.95.82 - G.30.B.54)
CS540, CS640, CS520, CS660
E123 - SWATH PLATE POSITION (B26) SENSOR SHORT CIRCUIT TO +VE

operation.
Cause:
1. Faulty connector
2. Faulty harness
Solution:
1. Check the swath plate position sensor connector X97 and the in-line harness connectors X98 and X5.

A. Disconnect connector X97 . Turn the key start ON. Measure the voltage between connector X97 pin 2,

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

12164 1 02/07/2004
K.64.C / 31

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 32
55_a3cs016 1
12164 1 02/07/2004
K.64.C / 33

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 34
vfil04cs0026h0a 2
12164 1 02/07/2004
K.64.C / 35

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 36
vfil04cs0027h0a 3
12164 1 02/07/2004
K.64.C / 37
Sensing system Swath plate position sensor - Open circuit

(K.64.C.95.82 - G.30.B.50)
CS540, CS640, CS520, CS660
E124 - SWATH PLATE (B26) POSITION SENSOR OPEN CIRCUIT

operation.
Cause:
1. Faulty connector
2. Faulty harness
3. Faulty swath plate position sensor
Solution:
1. Check the swath plate position sensor connector X97, CCM connector X142, and the in-line harness
connectors X98 and X5.



A. Turn the key start OFF. Remove the swath plate position sensor. Disconnect the rotary separator sensor
connector X32. Connect the suspect swath plate position sensor to connector X32. Turn the key start
ON. Check if the error code E121 is now also displayed. If error code E121 is displayed, replace the
swath plate position sensor.
the CCM.
12164 1 02/07/2004
K.64.C / 38

(A.30.A - C.20.E.15)
CS540 1260 > 1260
CS640 1260 > 1260

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 39
55_a3cs016 1
12164 1 02/07/2004
K.64.C / 40

CS540 1320 > 1324
CS640 1320 > 1324

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 41
vfil04cs0026h0a 2
12164 1 02/07/2004
K.64.C / 42

CS520 1376 > ....
CS540 1364 > ....
CS640 1364 > ....
CS660 1376 > ....

X19. Header 4360
Line: 4090 - 4420
12164 1 02/07/2004
K.64.C / 43
vfil04cs0027h0a 3
12164 1 02/07/2004
K.64.C / 44
Index
CROP PROCESSING - K

CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
CS540, CS640, CS520, CS660
Sensing system Swath plate position sensor - Open circuit (K.64.C.95.82 - G.30.B.50) 38
CS540, CS640, CS520, CS660
Sensing system Swath plate position sensor - Short circuit to B+ (K.64.C.95.82 - G.30.B.54) 31
CS540, CS640, CS520, CS660
Sensing system Swath plate position sensor - Short circuit to ground (K.64.C.95.82 - G.30.B.53) 24
CS540, CS640, CS520, CS660
12164 1 02/07/2004
K.64.C / 45
12164 1 02/07/2004
K.64.C / 46
CROP PROCESSING - K
PROTECTION SYSTEMS Reversing system - 90.C
CS540
CS640
CS520
CS660
12165 1 02/07/2004
K.90.C / 1
Contents
CROP PROCESSING - K
FUNCTIONAL DATA
PROTECTION SYSTEMS Reversing system - Logical diagram (K.90.C - C.20.B.72) 3

CS540, CS640, CS520, CS660
12165 1 02/07/2004
K.90.C / 2
CROP PROCESSING - PROTECTION SYSTEMS Reversing system
PROTECTION SYSTEMS Reversing system - Logical diagram

(K.90.C - C.20.B.72)
CS540, CS640, CS520, CS660
VFIL04CS0105H0A 1
Header reversing
12165 1 02/07/2004
K.90.C / 3
CROP PROCESSING - PROTECTION SYSTEMS Reversing system
HEADER REVERSING FIGURE KEY

K20 REVERSING MECHANISM RELAY
K27 ELECTRICAL REVERSING MECHANISM RELAY
K29 ELECTRICAL REVERSING MECHANISM RELAY
M2 ELECTRICAL REVERSER MOTOR
S16 HEADER ENGAGEMENT SWITCH
S20 REEL VARIATOR SLOW SWITCH
S81 REVERSING MECHANISM SWITCH
Y10 REVERSING MECHANISM SOLENOID
Y12 REVERSING MECHANISM (FORWARD) SOLENOID
Introduction:
A hydraulic as well as an electrical header reverser (CS520) is available.
The hydraulic header reversing mechanism can be engaged by the reversing mechanism switch (S81) on the back
of the Multifunction Handle (MFH). Whilst pushing the reversing mechanism switch (S81), the operator can rock the
header from reversing to forward with the reel variator slow switch (S20).
The header can not be rocked from reversing to forward on units with the electrical header reverser.
Initial conditions:
The threshing mode must be selected and threshing mechanism engaged.
When the initial conditions are met, a ground is supplied to the header reversing relay (K22), which cuts the power
supply to the header reversing mechanism switch (S81). Reversing mechanism relay K20 can not be activated.
This avoids the reverser engaging during normal running of the header.
When the header engagement switch (S16) is deactivated (header disengaged), it breaks the ground circuit, this
deactivates the header reversing mechanism relay (K22), which then supplies power to the header reversing
mechanism switch (S81). The reversing mechanism relay (K20) can now be activated by the reversing mechanism
switch (S81). When activated, power is supplied to the reversing mechanism solenoid (Y10) or activation of the
electrical reversing mechanism relay (K27) (units with electrical header reverser), reversing the rotation of the
header.
When the reel variator slow switch (S20) and the reversing mechanism switch (S81) are activated, power is supplied
to activate the header reversing mechanism relay (K21). This switches the power supply for the header reversing
mechanism solenoid (Y10) to the header reversing mechanism (forward) solenoid (Y12), the rotation of the header
is now forward slow (units with hydraulic header reverser only).
To prevent activation of the electrical reverser motor (M2) when the engine is not running, the electrical header
reversing mechanism relay (K29) is only activated with voltage from the D-contact on the alternator.
12165 1 02/07/2004
K.90.C / 4
Index
CROP PROCESSING - K
PROTECTION SYSTEMS Reversing system - Logical diagram (K.90.C - C.20.B.72) 3

CS540, CS640, CS520, CS660
12165 1 02/07/2004
K.90.C / 5
PRINTED IN BELGIUM
12151 1 02/07/2004
12151 1 02/07/2004
PRINTED IN BELGIUM
604_64_981_00 1 02/07/2004

CS Repair Manual 604.64.981.00

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REPAIR MANUAL

That information could be:

• the description of how to remove the cylinder head

• a table of specifications for a hydraulic pump

How to Use this Manual

Each Chapter is divided into four Information types:

SECTION B, POWER PRODUCTION

SECTION C, POWER TRAIN

SECTION E, BODY AND STRUCTURE

SECTION G, TOOL POSITIONING

SECTION K, CROP PROCESSING

ENGINE - Dynamic description (B.10.A - C.30.A.10)

Information Units and Information Search

example information unit Stack valve - Sectional View (A.10.A.18 - C.10.A.30)

• (1) Function and (2) Information type.

• (A) corresponds to the sections of the repair manual.

Page Header and Footer

• Section and Chapter description

The page footer will contain the following references:

• Publication number for that Manual, Section or Chapter.

• Version reference for that publication.

• Section, chapter and page reference e.g. A.10.A / 9

Safety rules ( - A.50.A.10)

WARNING AND DANGER SYMBOL

• Carefully follow specified repair and maintenance procedures.

• Take extra care if bystanders are present.

• Reduce the air pressure according to the local regulations in force.

• Do not run the engine in confined spaces without suitable ventilation.

• In order to check the pressure in the system use suitable instruments.

Wheels and Tyres

• Never cut or weld a rim mounted with an inflated tyre.

Removal and Re-fitting

Driveline overview ( - A.50.A.51)

MAIN OUTPUT SHAFT

UNLOADING OUTPUT SHAFT

Basic instructions ( - A.90.A.05)

ROTATING SHAFT SEALS

• remove any incrustations using a metal brush;

PROTECTING THE ELECTRONIC/ ELECTRICAL SYSTEMS DURING CHARGING OR

• Machine model (commercial name) and serial number

• essential for reliable repair operations

By using these tools, Repair Personnel will benefit from:

• operating in optimal technical conditions

• obtaining the best results

• saving time and effort

• working in safe conditions

Conversion factors ( - A.92.A.21)

Product identification ( - A.80.A.10)

EXPLANATION OF MACHINE SERIAL NUMBERS

CX-CS-TX Combine harvesters: 1

PRIMARY HYDRAULIC POWER SYSTEM A.10.A

PNEUMATIC SYSTEM A.20.A

ELECTRICAL POWER SYSTEM A.30.A

LIGHTING SYSTEM A.40.A

ELECTRONIC SYSTEM A.50.A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A

PRIMARY HYDRAULIC POWER SYSTEM - Torque (A.10.A - D.20.A.10) 4

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (A.10.A - C.20.B.20) 7