JOHN DEERE S780 COMBINES TM140819 PDF MANUAL

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combine Repair

REPAIR TECHNICAL MANUAL S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines TM140819 01DEC18 (ENGLISH)

John Deere Harvester Works

Introduction Foreword routine failures quickly.

Operation and tests sections help you identify the majority of

This manual is written for an experienced technician. Essential Information is organized in groups for the various components tools required in performing certain service work are identified in requiring service instruction. At the beginning of each group are this manual and are recommended for use.summarylistingsofallapplicableessentialtools,service equipment and tools, other materials needed to do the job, Live with safety: Read the safety messages in the introduction of service parts kits, specifications, wear tolerances, and torque this manual and the cautions presented throughout the text of the values. manual.

Technical Manuals are concise guides for specific machines.

They are on-the-job guides containing only the vital information CAUTION:needed for diagnosis, analysis, testing, and repair.

This is the safety-alert symbol. When you see this symbol on the Fundamental service information is available from other sources machine or in this manual, be alert to the potential for personal covering basic theory of operation, fundamentals of injury. troubleshooting, general maintenance, and basic type of failures and their causes.

Technical manuals are divided in two parts: repair and operation DX,TMIFC-19-20140415 and tests. Repair sections tell how to repair the components.

TM140819 (01.12.2018)

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Contents Section 10 - GeneralGroup 10 - Hydraulic Motors and Pumps Group 05 - SafetyGroup 15 - Hydraulic Valves Group 10 - SpecificationsGroup 20 - Hydraulic Cylinders Group 15 - Tune-Up and AdjustmentGroup 25 - Accumulators Group 20 - Fuels and Lubricants

Section 80 - Separator Shell Section 20 - EngineGroup 05 - Gull Wing Doors

Group 05 - Remove and Install EngineGroup 10 - Fiberglass Repair Group 10 - Cooling System

Section 90 - Operator Station Section 30 - Fuel and AirGroup 05 - Air Conditioner System (R134a) Group 05 - Air Intake SystemGroup 10 - System Components Group 10 - Diesel Fuel SystemGroup 15 - Cab

Section 40 - Electrical SystemSection 110 - Feeder House Group 05 - BatteriesGroup 05 - Conveyor Group 10 - Harness and Connector RepairGroup 10 - Top Shaft and Slip Clutch Group 15 - Wire Harness RoutingGroup15-FeederHouseDrivesandReverserGear Group 20 - Control Units and Power DistributionCase Group 25 - LightingGroup 20 - Fore/Aft and Lateral Tilt Frame Group 30 - Operators StationGroup25-FiveSpeedFeederHouseDriveGear Group 35 - Sensors and SwitchesCase Group 40 - Wiper

Group 45 - AlternatorSection 120 - Separator

Group 50 - Starting MotorGroup 05 - Separator Repair Group 55 - GreenStar™ ComponentsGroup 10 - Separator Drives Group 15 - Residue Disposal

Section 50 - Power TrainGroup20-ConveyorAugers,CleaningFanandChaffer

Group05-TransmissionandDifferential-ThreeSpeedand Sieve Frame TransmissionGroup 25 - Tailings Elevator and Augers Group10-HydrostaticSystem-ThreeSpeedGroup 30 - Primary Countershaft Gear Case TransmissionGroup 35 - Header Electromagnetic Clutch Group 15 - Transmission and Differential-Two-Range

Automatic TransmissionSection130-GrainTankandUnloading Group 20 - Hydrostatic Drive Pump-Two-Range System

Automatic TransmissionGroup 05 - Grain Tank Cross Augers Group25-HydrostaticDriveMotor-Two-RangeGroup 10 - Unloading Auger System Drives Automatic TransmissionGroup15-VerticalUnloadingAugerandLowerGear Group 30 - Single Reduction Final DriveCase Group 35 - Cam Lobe MotorGroup20-HorizontalUnloadingAugerandGear Group 40 - Tires and WheelsCase Group 45 - Standard TracksGroup 25 - Clean Grain Elevator Group 46 - Export TracksGroup 30 - Grain Tank and Covers

Section 60 - Steering and BrakesSection140-EngineGearCaseandControl Group 05 - SteeringValve Group 10 - BrakesGroup 05 - Engine Gear Case and Valve Group 15 - Brakes-Two-Range Automatic Transmission

Section 199 - Dealer Fabricated Tools Group 05 - Dealer Fabricated Tools

Section 70 - Hydraulic System Group 05 - Hydraulic Reservoir

TM140819 (01.12.2018)

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Section 10

General Page

Contents

Page

Unified Inch Bolt and Screw Torque Values..........10-10-9 Metric Bolt and Screw Torque Values....................10-10-10 Sealants and Adhesives Cross-Reference Chart..10-10-11 Face Seal Fittings Assembly and Installation-All 10-10-11 Pressure Applications....................................

Metric Face Seal and O-Ring Stud End Fitting 10-10-12 Torque Chart-Standard Pressures.................

Metric Face Seal and O-Ring Stud End Fitting 10-10-13 Torque Chart-High Pressure Applications......

SAE Face Seal and O-Ring Stud End Fitting 10-10-14 Torque Chart-Standard Pressures.................

SAE Face Seal and O-Ring Stud End Fitting 10-10-15 Torque Chart-High Pressure Applications......

Four Bolt Flange Fittings Assembly and 10-10-15

Group 05 - Safety Recognize Safety Information...............................10-05-1 Follow Safety Instructions......................................10-05-1 Service Tires Safely...............................................10-05-1 Understand Signal Words......................................10-05-2 Remove Paint Before Welding or Heating.............10-05-2 Handle Fluids Safely-Avoid Fires..........................10-05-2 Prevent Battery Explosions...................................10-05-3 Handling Batteries Safely......................................10-05-3 Prepare for Emergencies.......................................10-05-4 Prevent Acid Burns................................................10-05-4 Avoid High-Pressure Fluids...................................10-05-4 Service Accumulator Systems Safely....................10-05-5 Wait Before Opening High-Pressure Fuel 10-05-5 System...........................................................

Park Machine Safely..............................................10-05-5 Support Machine Properly.....................................10-05-5

Installation-All Pressure Applications.............

SAE Four Bolt Flange Cap Screw Torque Values- 10-10-16 Standard Pressure Applications.....................

SAE Four Bolt Flange Cap Screw Torque Values- 10-10-17 High Pressure Applications............................

Group 15 - Tune-Up and Adjustment

Wear Protective Clothing.......................................10-05-6 Service Machines Safely.......................................10-05-6 Work In Ventilated Area.........................................10-05-6 Illuminate Work Area Safely..................................10-05-6

Tune-Up and Adjustment.......................................10-15-1 Care and Maintenance of Belts.............................10-15-1

Replace Safety Signs............................................10-05-7 Use Proper Lifting Equipment................................10-05-7 Avoid Harmful Asbestos Dust................................10-05-7 Work in Clean Area...............................................10-05-7

Defective Belts......................................................10-15-3 Prevent Hydraulic System Contamination.............10-15-4 Check Oil Lines and Fittings..................................10-15-4 BasicElectricalComponentHandling/Precautions 10-15-5

Practice Safe Maintenance....................................10-05-8 Use Proper Tools...................................................10-05-8 Construct Dealer-Made Tools Safely.....................10-05-8

For Vehicles Equipped With Computer Controlled Systems........................................

Avoid Heating Near Pressurized Fluid Lines.........10-05-9 Decommissioning - Proper Recycling and Disposal 10-05-9 of Fluids and Components.............................

Use Adequate Service Facilities............................10-05-9 Live With Safety.....................................................10-05-10 Servicing Electronic Control Units.........................10-05-10 Welding Near Electronic Control Units..................10-05-10 Precautions for Welding........................................10-05-10 Keep Electronic Control Unit Connectors Clean....10-05-11 Clean Exhaust Filter Safely...................................10-05-11 Avoid Static Electricity Risk When Refueling.........10-05-12 Group 10 - Specifications Operating Speeds (S760 STS™ and S770 10-10-1 STS™)............................................................

OperatingSpeeds(S780STS™,S785STS™,and 10-10-2 S790 STS™)..................................................

Specifications (S760 STS™, and S770 STS™)....10-10-3 Specifications (S780 STS™, S785 STS™, and 10-10-5 S790 STS™)..................................................

Dimensions (S760 STS™, and S770 STS™).......10-10-7 Dimensions (S780 STS™, S785 STS™, and S790 10-10-8 STS™)............................................................

Dimension Reference Points.................................10-10-8

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Group 20 - Fuels and Lubricants Handling and Storing Diesel Fuel..........................10-20-1 Diesel Fuel............................................................10-20-2 Lubricity of Diesel Fuel..........................................10-20-2 Testing Coolant Freeze Point................................10-20-3 Diesel Engine Coolant (engine with wet sleeve 10-20-4 cylinder liners)................................................

Operating in Warm Temperature Climates............10-20-4 John Deere COOL-GARD™ II Coolant Extender..10-20-5 Water Quality for Mixing with Coolant 10-20-6 Concentrate....................................................

Diesel Exhaust Fluid (DEF) - Use in Selective 10-20-6 Catalytic Reduction (SCR) Equipped Engines..........................................................

Disposal of Diesel Exhaust Fluid (DEF)................10-20-6 Storing Diesel Exhaust Fluid (DEF).......................10-20-6 Testing Diesel Exhaust Fluid (DEF).......................10-20-7 Required Emission-Related Information................10-20-7 Diesel Engine Break-In Oil - Non-Emissions 10-20-8 Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III.......................

Diesel Engine Oil - Tier 2 and Stage II..................10-20-8 Diesel Engine Oil - Tier 3 and Stage III.................10-20-9 Diesel Engine Oil - Interim Tier 4, Final Tier 4, 10-20-9 Stage IIIB, and Stage IV.................................

John Deere Break-In Plus™ Engine Oil - Interim 10-20-9 S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Page

Page

Tier 4, Final Tier 4, Stage IIIB, and Stage IV..

Gear Case, and Two-Speed Separator Drive Gear Case......................................................

Feeder House Reverser Gear Case......................10-20-11

Hydrostatic Drive System, Main Hydraulic System, 10-20-10 Main Engine Gear Case, Tracks Tension, Mid and Rear Roller Hubs Oils..............................

Transmission (Non Two Range Automatic 10-20-11 Transmission Machines), Final Drives, Tracks Drive Gear Case, Loading Auger, Primary Countershaft, Flex Residue Overshot Beater

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Grease................................................................... 10-20-12 Corn Head Grease................................................10-20-12 Brake Fluid............................................................10-20-12

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

For the full PDF version of this manual, Please click on the above download PDF button.

Safety

Group 05 Safety Recognize Safety Information

T81389-UN: Safety-alert symbol

This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

DX,ALERT-19-19980929

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.

Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your

Follow Safety Instructions John Deere dealer.

Therecanbeadditionalsafetyinformationcontainedonpartsand components sourced from suppliers that is not reproduced in this

operator′s manual.

Learn how to operate the machine and how to use controls

properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or

safety and affect machine life.

If you do not understand any part of this manual and need TS201-UN: Safety Messagesassistance, contact your John Deere dealer.

DX,READ-19-20090616

Service Tires SafelyDonotattempttomountatireunlessyouhavetheproper equipment and experience to perform the job.

deform the wheel.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or Wheninflatingtires,useaclip-onchuckandextensionhoselong enough to allow you to stand to one side and NOT in front of or

over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims, or

missing lug bolts and nuts.

Wheels and tires are heavy. When handling wheels and tires use a safe lifting device or get an assistant to help lift, install, or

remove.

RXA0103438-UN: Explosive Tire and Rim PartsDX,WW,RIMS-19-20170228

Explosive separation of a tire and rim parts can cause serious injury or death.

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety DANGER ; The signal word DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Understand Signal Words

WARNING ; The signal word WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION ; The signal word CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events which could lead to personal injury.

A signal word—DANGER, WARNING, or CAUTION—is used withthesafety-alertsymbol.DANGERidentifiesthemostserious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safetysigns.CAUTIONalsocallsattentiontosafetymessagesin this manual.

TS187-19: Signal Words

DX,SIGNAL-19-20161005

Remove Heating

Paint

Before Welding

or

Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take

place.

TS220-UN: Toxic Fumes

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint welding, soldering, or using a torch.

Remove paint before heating:

Do all work in an area that is well ventilated to carry toxic fumes and dust away. isheatedbyDispose of paint and solvent properly.

DX,PAINT-19-20020724

TS227-UN: Avoid Fires

Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

DX,FLAME-19-19980929

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety

Prevent Battery Explosions

TS204-UN: Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

DX,SPARKS-19-19930303

Handling Batteries Safely

TS203-UN: Caution

Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always remove grounded (-) battery clamp first and replace grounded clamp last.

Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid hazards by:

Filling batteries in a well-ventilated area Wearing eye protection and rubber gloves Avoiding use of air pressure to clean batteries Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripping electrolyte Using correct battery booster or charger procedure.

TS204-UN: Caution

If acid is spilled on skin or in eyes:

Flush skin with water.

Apply baking soda or lime to help neutralize the acid.

Flush eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

Do not induce vomiting.

Drink large amounts of water or milk, but do not exceed 2 L (2 qt.).

Get medical attention immediately.

Battery posts, terminals, and related accessories WARNING: contain lead and lead compounds, chemicals known to the State of California cause cancer and reproductive harm. Wash hands afterto handling.

DX,WW,BATTERIES-19-20101202

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety

Prepare for Emergencies

TS291-UN: First Aid Kit

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

DX,FIRE2-19-19930303

Prevent Acid Burns

TS203-UN: Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

Avoiding spilling or dripping electrolyte.

Use proper jump start procedure.

If you spill acid on yourself:

Flush your skin with water.

Apply baking soda or lime to help neutralize the acid.

Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

Do not induce vomiting.

Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

Get medical attention immediately.

DX,POISON-19-19930421

Replace worn or damaged hose assemblies immediately with

Avoid High-Pressure Fluids John Deere approved replacement parts.

Escaping fluid under pressure can penetrate the skin causing

serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying

pressure.

Search for leaks with a piece of cardboard. Protect hands and

body from high-pressure fluids.

X9811-UN: High Pressure

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling

1-800-822-8262 or +1 309-748-5636.

Inspect hydraulic hoses periodically – at least once per year – DX,FLUID-19-20111012 for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety

Service Accumulator Systems Safely

TS281-UN: Hydraulic Accumulator

Escaping fluid or gas from pressurized hydraulic accumulator systems can cause serious injury. Extreme heat can cause the accumulator to burst, and pressurized lines can be accidentally cut. Do not weld or use a torch near a pressurized accumulator or pressurized line.

Relieve pressure from the hydraulic system before removing accumulator. Never attempt to relieve hydraulic system or accumulator pressure by loosening a fitting.

Accumulators cannot be repaired.

DX,WW,ACCLA-19-20030415

Wait Before Opening High-Pressure TS1343-UN: High-Pressure Fuel Lines High-pressure fluid remaining in fuel lines can cause serious Fuel System injury. Only technicians familiar with this type of system should

perform repairs. Before disconnecting fuel lines, sensors, or any other components between the high-pressure fuel pump and nozzles on engines with High-Pressure Common Rail (HPCR) fuel system, confirm that the fuel pressure is relieved.

DX,WW,HPCR2-19-20140909

Park Machine Safely

TS230-UN: Remove the Key

Before working on the machine:

Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag station.

in operator DX,PARK-19-19900604

Support Machine Properly

TS229-UN: Support Properly

Always lower the attachment or implement to the ground before youworkonthemachine.Iftheworkrequiresthatthemachineor attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.

DX,LOWER-19-20000224

TM140819 (01.12.2018)

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety

Wear Protective Clothing

TS206-UN: Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,WEAR-19-19900910

Service Machines Safely

TS228-UN: Moving Parts

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

DX,LOOSE-19-19900604

Work In Ventilated Area

TS220-UN: Engine exhaust fumes

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

Ifyoudonothaveanexhaustpipeextension,openthedoorsand get outside air into the area.

DX,AIR-19-19990217

Illuminate Work Area Safely

TS223-UN: Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

DX,LIGHT-19-19900604

TM140819 (01.12.2018)

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety

Replace Safety Signs

TS201-UN: Safety Signs

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

DX,SIGNS1-19-19900604

Use Proper Lifting Equipment

TS226-UN: Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

DX,LIFT-19-19900604

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and somegaskets.Theasbestosusedinthesecomponentsisusually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for cleaning.

Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

DX,DUST-19-19910315

TS220-UN: Asbestos Dust

Work in Clean Area

T6642EJ-UN: Clean Work Area

Before starting a job:

Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.

DX,CLEAN-19-19900604

TM140819 (01.12.2018)

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety

Practice Safe Maintenance

TS218-UN: Keep Area Clean

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving.

Keep hands, feet, and clothing away from power-driven parts.

Disengage all power and operate controls to relieve pressure.

Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable () before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Falling while cleaning or working at height can cause serious injury. Use a ladder or platform to easily reach each location. Use sturdy and secure footholds and handholds.

DX,SERV-19-20170228

Use Proper Tools

TS779-UN: Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

Forlooseningandtighteninghardware,usethecorrectsizetools.

DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

DX,REPAIR-19-19990217

Construct Dealer-Made Tools Safely

LX1016749-UN: Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.

Do not weld tools unless you have the proper equipment and experience to perform the job.

DX,SAFE,TOOLS-19-19971010

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety

Avoid Heating Near Pressurized Fluid TS953-UN: Flammable Spray Flammable spray can be generated by heating near pressurized Lines fluid lines, resulting in severe burns to yourself and bystanders.

Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

DX,TORCH-19-20041210

Decommissioning — Proper Recycling and Disposal of Fluids and Components

TS1133-UN: Recycle Waste

Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:

Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials.

Follow instructions for specialized components.

Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.

Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately.

Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers.

Do not pour waste fluids onto the ground, down a drain, or into any water source.

Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes.

Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.

Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely.

Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste.

DX,DRAIN-19-20150601

Be sure all electrical outlets and tools are properly grounded.

Use Adequate Service Facilities Use adequate light for the job at hand.

Keeptheserviceareacleananddry.WetoroilyfloorsareService the machine on a level, hard-surfaced area. slippery. Wet spots can be dangerous when working with Use lifting equipment and safety stands which have adequate electrical equipment. strength for the job being performed.

Make sure the service area is adequately vented.HX,1401,1005,A-19-19921211 Periodically check the shop exhaust system for leakage. Engine exhaust gas is dangerous.

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S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety

Live With Safety

TS231-19: Safety Systems

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

DX,LIVE-19-19920925

Servicing Electronic Control Units

3. The wiring harness terminals and connectors for electronic control units are repairable.

IMPORTANT: 1. Do not open control unit and do not clean with a highpressure spray. Moisture, dirt, and other contaminants can cause permanent damage.

4. IMPORTANT: If an electronic control unit is not programmed identical to the original control unit, misleading diagnostic messages and poor performance will occur.

Control units are not repairable; replace only if indicated in the diagnostic procedure.

Before putting back into service, verify that the control unit is programmed identical to the original control unit.

2. Since control units are the components LEAST likely to fail, isolate failure before replacing by completing the diagnostic procedure.

Welding Near Electronic Control Units

DX,WW,ECU01-19-20151002

IMPORTANT: 1. Do not jump-start engines with arc welding equipment.

Currents and voltages are too high and may cause permanent damage.

Disconnect the negative (-) battery cable(s).

2

Disconnect the positive (+) battery cable(s).

.

Connect the positive and negative cables together. Do not attach to vehicle frame.

Clear or move any wiring harness sections away from welding area.

Connect welder ground close to welding point and away from control units.

After welding, reverse Steps 1—5.

3 .

4 TS953-UN: Welding Graphic

.

5

Precautions for Welding

DX,WW,ECU02-19-20090814

.

stripper, remove with soap and water before welding.

Remove solvent or paint stripper containers and other 6 Remove paint before welding or heating (see Safety Section in flammable material from area before welding. Allow fumes this manual for more information on paint removal and high- to disperse at least 15 minutes before welding or heating. . pressure lines).

IMPORTANT: Welding on the engine is NOT ALLOWED. If welding must be performed on the machine, follow these precautions.

CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well IMPORTANT: ventilated area. Dispose of paint and solvent properly. If High currents or electrostatic discharge into electronic you sand or grind paint, avoid breathing the dust by components from welding may cause permanent damage. wearing an approved respirator. If you use solvent or paint

TM140819 (01.12.2018)

10-05-10

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety 2. Disconnect the negative (-) battery cable(s) or open battery (-) switch if equipped.

3. Disconnect the positive (+) battery cable(s) or open battery (+) switch if equipped.

4. Clear or move any wiring harness sections away from the welding area.

5.Welding on engine components is not allowed.

6. Never connect the welder ground to any engine component or engine driven components that may be connected to the engine.

7.After welding, reverse steps 2—3.

DX,WELDING,PRECAUTIONS-19-20101206

TS953-UN: Welding Precaution

1. Remove paint from the area to be welded and ground cable clamp location.

Keep Electronic Connectors Clean

Control

Unit

3. Observe the locking mechanism of the connector when disconnecting and reconnecting.

4. Do not pull on wires to disconnect.

5. Before reconnecting:

IMPORTANT: 1. Keep terminals clean and free of foreign debris.

Moisture, dirt and other contaminants may cause the terminals to erode over time and not make a good electrical connection.

If a connector is not in use, put on the proper dust cap or an appropriate seal to protect it from foreign debris and moisture.

Look for bent terminals; do not force connectors into each other.

Replace any terminal where corrosion exists.

Clean the connector of any foreign debris.

Dry the connector of any moisture.

6. When reconnecting, make sure seals around the connector pairs are functional.

DX,WW,ECU03-19-20090611

IMPORTANT: 2. Do not probe through the wire insulation or through the back of the connector. Do not insert items such as paper clips or wires into connector terminals.

Make measurements on a connector terminal using JDG10466 Flex Probe Kit in SERVICEGARD.

Clean Exhaust Filter Safely

TS271-UN: Hand Over Flame

TS227-UN: Fire Safety

TM140819 (01.12.2018)

10-05-11

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Safety Keep machine away from people, animals, or structures which may be susceptible to harm or damage from hot exhaust gases or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can melt, burn, or explode.

Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning.

Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and clean up any spilled fuel.

Always make sure that engine is stopped while hauling machine on a truck or trailer.

TS1693-UN: Moving Parts

Contact with exhaust components while still hot can result in serious personal injury.

Avoid contact with these components until cooled to safe temperatures.

If service procedure requires engine to be running:

Only engage power-driven parts required by service procedure Ensure that other people are clear of operator station and machine Keep hands, feet, and clothing away from power-driven parts.

Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before Duringexhaustfiltercleaningoperations,theenginemayrunleaving the operator’s station. at elevated idle and hot temperatures for an extended period Shut off engine and remove key (if equipped) before leaving the of time. Exhaust gases and exhaust filter components reach machine unattended. temperatures hot enough to burn people, or ignite or melt DX,EXHAUST,FILTER-19-20110112 common materials.

TS1695-UN: Stop

AvoidStaticElectricityRiskWhenRG21992-UN: Static Discharge (Fuel Nozzle) Refueling The removal of sulfur and other compounds in Ultra-Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability to store a static charge.

Refineries may have treated the fuel with a static dissipating additive. However, there are many factors that can reduce the

effectiveness of the additive over time.

Static charges can build up in ULSD fuel while it is flowing through fuel delivery systems. Static electricity discharge when combustiblevaporsarepresentcouldresultinafireorexplosion.

Therefore, it is important to ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded.

Consult with your fuel or fuel system supplier to ensure that the deliverysystemisincompliancewithfuelingstandardsforproper

grounding and bonding practices.

RG22142-UN: Explosion

TM140819 (01.12.2018)

DX,FUEL,STATIC,ELEC-19-20130712

10-05-12

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Specifications

Group 10 Specifications Operating Speeds (S760 STS™ and S770 STS™)

Feed Accelerator Speeds

Speeds shown are average and can vary from machine to machine.

Feed Accelerator (Optional Slow Speed)

310/770 rpm

Feed Accelerator (High-Speed High Capacity)

520/970 rpm

Engine Speeds

to

(9.0 L Tier 2/Stage II and Tier 3/ Stage IIIA) Engine

(9.0 L Final Tier 4/Stage IV) Engine

1200 rpm

1200 rpm

1690 rpm

1690 rpm

2340 rpm

2340 rpm

2200 rpm

2200 rpm

Slow Idle (Separator Off) Mid Speed (Separator Off) Fast Idle (Separator Off) Rated Speed (Separator On)

Jackshaft Speeds

Front Right-Hand Jackshaft

518

Rear Right-Hand Jackshaft

rpm 518 rpm

Cleaning Fan Speeds Standard Speed

620—1350

Special Slow Speed

rpm 250—500 rpm

Elevator Speeds

1453 rpm

Separator Drive Shaft Speed

1453 rpm

Main Countershaft Speed

Separator Speeds

995 rpm

998 rpm

NOTE: Operating speed specifications and design subject change without notice.

S770

S760

Discharge Beater Speed

S760

S770

Clean Grain Elevator

417 rpm415 rpm

Clean Grain Loading Auger

448 rpm445 rpm

Tailings Elevator, Lower Auger

395 rpm

Tailings Elevator, Upper Auger

625 rpm

Shoe Drive

298 rpm

Conveyor Augers

420 rpm

S760

S770

High Range

380—1000

400—1000

Unloading System Speeds (Separator Engaged)

Low Range

rpm 210—530

rpm 210—530

Unloading System Countershaft

1000

rpm

rpm

Unloading Auger Gearbox, Input Shaft

rpm 460

Unloading Vertical Auger

rpm 460

Unloading Outer Auger

rpm 460

Grain Tank Horizontal Augers (Front and Rear)

rpm 330

Feeder House Lower Shaft Speeds Fixed Speed (If Equipped)

490 rpm

Heavy-Duty Variable Speed (If Equipped)

490—750 rpm

High Torque Variable Speed (If Equipped)

490—750 rpm

Multi-Speed (If Equipped)

First Gear: 480 rpm Second Gear: 535 rpm Third Gear: 590 rpm Fourth Gear: 665 rpm Fifth Gear: 735 rpm

rpm Chopper Speeds

Chopper/Discharge Beater Jackshaft Chopper (Two Speeds) Overshot Beater

Feed Accelerator Speeds Feed Accelerator (Standard Speed)

TM140819 (01.12.2018)

Deluxe Residue

Intermediate Residue

Premiu m Residue

1880 rpm

2045 rpm

2045 rpm

1505/2350 rpm Not Applicable

1400/2995 rpm

1400/2995 rpm Not

995 rpm

Applicable 430/780 rpm

10-10-1

OUO6083,0001573-19-20170111

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Specifications

Operating Speeds (S780 STS™, S785 STS™, and S790 STS™) Speeds shown are average and can vary from machine to machine.

995 rpm

Discharge Beater Speed Jackshaft Speeds Front Right-Hand Jackshaft

520

Rear Right-Hand Jackshaft

rpm 520

NOTE:

rpm

Cleaning Fan Speeds

Operating speed specifications and design subject change without notice.

to

Standard Speed

620—1350

Special Slow Speed

rpm 250—500 rpm

Engine Speeds

(13.5 L Tier 2/Stage II and Tier 3/ Stage IIIA) Engine

(13.5 L Final Tier 4/Stage IV) Engine

Slow Idle (Separator Off)

1200 rpm

1200 rpm

1690 rpm

1690 rpm

Mid Speed (Separator Off) Fast Idle (Separator Off) Rated Speed (Separator On)

2240 rpm

2240 rpm

2100 rpm

2100 rpm

Elevator Speeds

S780 and S785

S790

Clean Grain Elevator

415 rpm

460 rpm 415 rpm (HillMaster™)

Clean Grain Loading Auger

450 rpm

500 rpm 450 rpm (HillMaster™) 490 rpm

Tailings Elevator, Lower Auger Tailings Elevator, Upper Auger

580 rpm

Shoe Drive

300 rpm

Conveyor Augers

425 rpm

1466 rpm

Separator Drive Shaft Speed

Unloading System Speeds (Separator Engaged)

1466 rpm

Main Countershaft Speed

Separator Speeds High Range

400—1000

Low Range

rpm 210—530

1005 rpm

Unloading Auger Gearbox, Input Shaft

460 rpm 465 rpm (HillMaster™) 460 rpm 465 rpm (HillMaster™) 460 rpm 465 rpm (HillMaster™) 450 rpm 335 rpm (HillMaster™)

Unloading Vertical Auger Unloading Outer Auger

rpm 880 rpm

Tailings System Speed

Unloading System Countershaft

Grain Tank Horizontal Augers (Front and Rear)

Feeder House Lower Shaft Speeds Fixed Speed Multi-Speed

Chopper Speeds

490 rpm First Gear: 480 rpm Second Gear: 535 rpm Third Gear: 590 rpm Fourth Gear: 665 rpm Fifth Gear: 735 rpm

Chopper/Discharge Beater Jackshaft Chopper (Two Speeds) Overshot Beater

Deluxe Residue

Intermediate Residue

Premiu m Residue

1880 rpm

2045 rpm

2045 rpm

1505/2350 rpm Not Applicable

1400/2995 rpm

1400/2995 rpm Not

995 rpm

Applicable

Feed Accelerator Speeds

OUO6083,0001574-19-20170111

Feed Accelerator (Standard Speed)

430/780

Feed Accelerator (Optional Slow Speed)

rpm

Feed Accelerator (High-Speed High Capacity)

310/770 rpm 520/970 rpm

TM140819 (01.12.2018)

10-10-2

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Specifications

Specifications (S760 STS™, and S770 STS™) NOTE: Specifications and design subject to change without notice.

Separator Elements Threshing Elements (Variable Stream Rotor)

Corn/Small Grain: 15 Rice Option: 15 elements and 12 threshing tines in dense pack locations

Tines (TriStream™ Rotor)

24

Tines (Variable Stream Rotor)

20

Concave Engine Make

John Deere 6090HH006 Export (9.0 L Tier 2/Stage II) 6090HH026 Export (9.0 L Tier 3/Stage IIIA) 6090HH027 Export (9.0 L Tier 3/Stage IIIA) 6090HH028 (9.0 L Final Tier 4/Stage IV)

Model

Type

Six-cylinder, in line, valve-in-head (four valves), air-toair aftercooled diesel turbocharged S760 S770

Rated Power (Tier 2/Stage II and Tier 3/Stage IIIA) Rated Power (Final Tier 4/ Stage IV) Rated Speed

239 kW (320 hp)278 kW (373 hp)

Number of Concaves

3

Number of Bars Per Concave

Grain—Front 25, Mid/rear 25; Corn 31

Separator Number of Grates

Discharge Grate Number of Grates

3

249 kW (334 hp)292 kW (392 hp) 2200 rpm2200 rpm

Power Boost at Rated Speed

25 kW (34 hp)25 kW (34 hp)

Peak Power (Tier 2/Stage II and Tier 3/Stage IIIA) Peak Power (Final Tier 4/ Stage IV) Peak Power Speed (Rated Speed -200 rpm) Displacement

Discharge Beater

S760 and S770

S770 HillMaster™

Number of Wings

Standard: 5 Tough Crop: 8

Tough Crop: 8

272 kW (365 hp)317 kW (425 hp) 285 kW (382 hp)335 kW (449 hp)

Grain Tank

2000 rpm2000 rpm

10 572 L (300 bu) Capacity Extensions

9.0 L (549 in³)9.0 L (549 in³)

Firing Order

1-5-3-6-2-4 1-5-3-6-2-4

Air Cleaner

10 572 L (300 bu) Covers

Average Unloading Rate, 116 L/s (3.3 bu/s) Unload Rate6977 L/min (198 bu/min)

Dry type with safetyDry type with safety element element

Maximum Unloading Rate, 116 L/s (3.3 bu/s) Unload 7612 L/min (216 bu/min) Rate

Weight

Electrical System Battery Voltage

12 Volts

Battery Terminal Grounded

Negative

Alternator (Tier 2/Stage II) Alternator (Tier 3/Stage IIIA) Alternators (Final Tier 4/Stage IV)

200 A

S760

S770

Machine Weight [Weight is based on corn machine configuration 19 with 950 L (250 gal) of diesel fuel in the fuel tank, empty grain tank, 504 kg and no header attached.]

(43 006 lb)

19 842 kg (43 752 lb)

Turning Radius

Transmission Speeds (Mechanical Shift Machines)

Three Speeds

Speeds (Push-Button Shift Machines)

Three Speeds

Speeds (Two-Range Automatic Transmission Machines)

Two Speed Auto Shift

Rear Wheel Tread Width

3.35 m (10 ft 10 in)

Turning Radius (Non-Powered Axles)

8.02 m (26 ft 3 in)

Turning Radius (Powered Axles)

7.73 m (25 ft 4 in)

Capacities

S760

Type (Mechanical Shift Machines)

Hydraulic Shoe

Type (Push-Button Shift Machines)

Hydraulic Shoe

Type (Two-Range Automatic Transmission Machines)

Multiple Wet Discs

Feed Accelerator

S760 and S770

S770 HillMaster™

Number of Wings

Standard: 10 Tough Crop: 8 Rice: 5

Tough Crop: 8

Diesel Exhaust Fluid (DEF) Tank (Final Tier 4/Stage IV) Cooling System with heater (Tier 2/Stage II and Tier 3/ Stage IIIA)

29 L (7.6 gal) Optional 52.2 L (13.8 gal) Standard

Cooling System with heater (Final Tier 4/Stage IV) Engine Crankcase with filter (Tier 2/Stage II and Tier 3/ Stage IIIA)

53 L (56 qt)

Engine Crankcase with filter (Final Tier 4/Stage IV) Transmission (Mechanical Shift and Push-Button Shift Machines)

Separator Elements

Final Drives

Corn/Small Grain: 15

TM140819 (01.12.2018)

10-10-3

S770 760 L (200 gal) Optional 950 L (250 gal) Standard

Fuel Tank Brakes

Threshing Elements (TriStream™ Rotor)

4

53 L (56 qt)

27.5 L (29 qt) [It is vital to maintain engine oil at correct levels. Always verify that oil level is at correct location on dipstick when servicing.]

27.5 L (29 qt) [It is vital to maintain engine oil at correct levels. Always verify that oil level is at correct location on dipstick when servicing.]

9.6 L (10 qt) 8 L (8.5 qt)8 L (8.5 qt)

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

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