JOHN DEERE S430 COMBINE TM805219 PDF MANUAL

Series S430 and S440 Combines Diagnostic

DIAGNOSTIC TECHNICAL MANUAL Series S430 and S440 Combines TM805219 01DEC18 (ENGLISH)

John Deere Horizontina

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.

TM805219 (01.12.2018)

Series S430 and S440 Combines

Contents

Section 210 - GeneralGroup40H-Fuel,AirIntake,ExhaustandCooling-V

Group 05 - SafetyComponents Group 10 - Combine and Component Identification

Group 15 - General SpecificationsSection 240 - Electrical System

Group 20 - Diagnostic and Testing ProceduresGroup 5A - General Information Group 10A - Calibration Procedures

Section 211 - Diagnostic Trouble CodesGroup 10B - Tests and Adjustments

Group 05 - Accessing Diagnostic Codes and Group 20A - Cab/Operator`s Station - Theory of

Addresses Operation

Group AIC - Armrest ControllerGroup20B-AgManagementSolutions-Theoryof Group AYM - Ag Leader Moisture SensorOperation Group CAB - CAB Control UnitGroup 20C - Lighting - Theory of Operation Group E00 - CPM - Compact Power ModuleGroup 20D - Engine/Fuel - Theory of Operation Group E01 - I/O Extender Control UnitGroup20E-Starting/Charging/PowerDistributionGroupECU-EngineControlUnit-Tier0/TierIIITheory of Operation Engines Group 20F - Feeder House and Header Functions Group GLM - Grain Loss Monitor Control UnitTheory of Operation Group HC1 - Harvester Control UnitGroup20H-Threshing/Separating/Cleaning-Theoryof Group HC3 - Harvester Control UnitOperation Group HHC - Harvest Machine ControlGroup20I-GrainTank/Unloading-Theoryof Group HIM - Instrument ClusterOperation Group ITC - Vehicle NavigationGroup20J-ResidueSystem-TheoryofOperation Group MHC - Multi-Function Lever Control UnitGroup20K-Transmission/GroundDriveSystemsGroup PDU - Primary Display UnitTheory of Operation Group SCL - Steering Control UnitGroup20L-HydraulicOil/Pressure-Theoryof Group VTI - Virtual TerminalOperation Group VTV - Virtual TerminalGroup 20M - Brakes - Theory of Operation Group XMC - Brakes System ControllerGroup20N-AirCompressorSystem-Theoryof Group XSC - Steering ControllerOperation Group 30A - Cab/Operators Station - Schematics

Section 212 - Observable SymptomsGroup30B-AgManagementSolutions-

Group 230 - Air Intake and Cooling SystemsSchematics Group 240 - Electrical SystemGroup 30C - Lighting - Schematics Group 245 - Electrical Control UnitsGroup 30D - Engine/Fuel - Schematics Group 250 - DrivesGroup30E-Starting/Charging/PowerDistributionGroup 260 - Steering and BrakesSchematics Group 270 - Hydraulic SystemGroup30F-FeederHouseandHeaderFunctionsGroup 290 - Cab/Open Operator StationSchematics Group 30H - Threshing/Separating/Cleaning -

Section 220 - Engine SystemSchematics

Group 20 - Engine SystemsGroup 30I - Grain Tank/Unloading - Schematics Group 30J - Residue System - Schematics

Cooling Schematics

Section 230 - Air Intake, Exhaust and Group 30K - Transmission/Ground Drive Systems -

Group 20 - Theory of OperationGroup 30L - Hydraulic Oil/Pressure - Schematics Group 30 - SchematicsGroup 30M - Brakes - Schematics Group 50 - DiagnosticsGroup 30N - Air Compressor System - Schematics Group 50A - Cab/Operator`s Station - Diagnostics

Section 239 - Air Intake, Exhaust and Group 50B - Ag Management Solutions Cooling - ComponentsDiagnostics Group 50C - Lighting - Diagnostics

Group 40A - Fuel, Air Intake, Exhaust and Cooling - A Group 50D - Engine/Fuel - Diagnostics Components Group 40B - Fuel, Air Intake, Exhaust and Cooling - D Diagnostics Components Group 40C - Fuel, Air Intake, Exhaust and Cooling - F Diagnostics Components Group 40D - Fuel, Air Intake, Exhaust and Cooling - H Diagnostics Components Group 50I - Grain Tank/Unloading - Diagnostics Group 40E - Fuel, Air Intake, Exhaust and Cooling - P Group 50J - Residue System - Diagnostics Components Group 40F - Fuel, Air Intake, Exhaust and Cooling - R Diagnostics Components Group 50L - Hydraulic Oil/Pressure - Diagnostics Group 40G - Fuel, Air Intake, Exhaust and Cooling - S Group 50M - Brakes - Diagnostics Components Group 50N - Air Compressor System - Diagnostics TM805219 (01.12.2018)

Group 50E - Starting/Charging/Power Distribution Group 50F - Feeder House and Header Functions Group 50H - Threshing/Separating/Cleaning -

Group 50K - Transmission/Ground Drive Systems -

Series S430 and S440 Combines

Section 245 - Electrical Control UnitsGroup 50 - Diagnostics Group 05 - Electrical Control Units - Summary of

References Section 269 - Steering and Brakes Group 10A - Accessing Diagnostic Trouble Codes and Components

Addresses Group 05 - Steering and Brakes - Components Group 10B - Diagnostic Addresses by Control UnitSummary of References Group 20 - Theory of Operation

Group 30 - SchematicsSection 270 - Hydraulic System

Group 50 - DiagnosticsGroup 10A - Preliminary and Operational Checks Group 10B - Hydraulic Specification

Section249-ElectricalConnector-Group 20 - Theory of Operation ComponentsGroup 30 - Schematics Group 40 - General InformationGroup 50 - Diagnostics Group 40W - Wiring Harnesses

Group 40X - Connectors - XSection279-HydraulicSystemGroup 40XA - Connectors - XAComponents

Group 40XB - Connectors - XBGroup05-Hydraulic-Components-Summaryof Group 40XE - Connectors - XEReferences Group 40XF - Connectors - XFGroup 40A - Hydraulic - A Components Group 40XG - Connectors - XGGroup 40B - Hydraulic - B Components Group 40XH - Connectors - XHGroup 40C - Hydraulic - C Components Group 40XK - Connectors - XKGroup 40D - Hydraulic - D Components Group 40XM - Connectors - XMGroup 40F - Hydraulic - F Components Group 40XR - Connectors - XRGroup 40G - Hydraulic - G Components Group 40XS - Connectors - XSGroup 40H - Hydraulic - H Components Group 40XW - Connectors - XWGroup 40M - Hydraulic - M Components Group 40XX - Connectors - XXGroup 40O - Hydraulic - O Components Group 40XY - Connectors - XYGroup 40P - Hydraulic - P Components Group 40R - Hydraulic - R Components

Section 250 - DrivesGroup 40S - Hydraulic - S Components

Group 10A - Preliminary & Operational ChecksGroup 40V - Hydraulic - V Components Group 10B - Hydraulic SpecificationsGroup 40X - Hydraulic - X Components Group 20 - Theory of OperationGroup 40Y - Hydraulic - Y Components Group 30 - Schematics

Group 50 - DiagnosticsSection 290 - Cab-Open Operator`s Station Group 10D - Specifications

Section 259 - Drives - ComponentsGroup 20 - Theory of Operation Group05-Drives-Components-SummaryofGroup 30 - Schematics ReferencesGroup 50 - Diagnostics

Section 260 - Steering and BrakesSection299-Cab-Operator`sStationGroup 10A - Preliminary & Operational ChecksComponents Group 20 - Theory of OperationComponents Group 30 - Schematics

TM805219 (01.12.2018)

Group 10B - Hydraulic SpecificationsGroup40A-Cab/OpenOperatorStation

Series S430 and S440 Combines

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Section 210 Contents

General Page

Page

Identification Numbers...........................................210-10-1 Identification Plates...............................................210-10-1 Machine Identification Plate Location....................210-10-1 Engine Serial Number...........................................210-10-1 Hydrostatic Drive Unit Pump.................................210-10-1 Hydrostatic Drive Unit Motor.................................210-10-2 Two Speed Four-Wheel Drive Motor.....................210-10-2 Rotor Drive Gearcase............................................210-10-2 Transmission......................................................... 210-10-2 Feeder House Reverser........................................210-10-3

Group 05 - Safety Recognize Safety Information...............................210-05-1 Handle Fluids Safely-Avoid Fires..........................210-05-1 Prepare for Emergencies.......................................210-05-1 Prevent Battery Explosions...................................210-05-2 Prevent Acid Burns................................................210-05-2 Handle Chemical Products Safely.........................210-05-2 Handle Starting Fluid Safely..................................210-05-3 Avoid High-Pressure Fluids...................................210-05-3 Park Machine Safely..............................................210-05-3 Support Machine Properly.....................................210-05-4 Wear Protective Clothing.......................................210-05-4 Protect Against Noise............................................210-05-4

Hydraulic Designators...........................................210-10-3 Hydraulic Circuit Symbols.....................................210-10-4

Work in Clean Area...............................................210-05-4 Work In Ventilated Area.........................................210-05-5 Precautions for Welding........................................210-05-5 Illuminate Work Area Safely..................................210-05-5 Service Machines Safely.......................................210-05-6 Construct Dealer-Made Tools Safely.....................210-05-6 Service Cooling System Safely.............................210-05-6 Service Accumulator Systems Safely....................210-05-6 Wait Before Opening High-Pressure Fuel 210-05-7 System...........................................................

Replace Safety Signs............................................210-05-7 Use Proper Lifting Equipment................................210-05-7

Group 15 - General Specifications CARB Non-road Emissions Control Warranty 210-15-2 Statement-Compression Ignition....................

EPA Non-road Emissions Control Warranty 210-15-8 Statement-Compression Ignition....................

Engine................................................................... 210-15-9 Electrical System...................................................210-15-9 Transmission and Brakes......................................210-15-9 Feeding................................................................. 210-15-9 Separator............................................................... 210-15-10 Discharge.............................................................. 210-15-10 Elevators and Cleaning Fan..................................210-15-10 Unloading.............................................................. 210-15-10 Turning Radius......................................................210-15-11

Remove Paint Before Welding or Heating.............210-05-8 Avoid Heating Near Pressurized Fluid Lines.........210-05-8 Service Tires Safely...............................................210-05-9 Avoid Harmful Asbestos Dust................................210-05-9 Practice Safe Maintenance....................................210-05-10 Use Proper Tools...................................................210-05-10 Decommissioning - Proper Recycling and Disposal 210-05-10 of Fluids and Components.............................

Live With Safety.....................................................210-05-11

Weight................................................................... 210-15-11 Capacities.............................................................. 210-15-11 Dimensions S430 and S440..................................210-15-12 Unified Inch Bolt and Screw Torque Values..........210-15-15 Metric Bolt and Screw Torque Values....................210-15-16 Group 20 - Diagnostic and Testing Procedures Troubleshooting..................................................... 210-20-1

Group 10 - Combine and Component Identification

TM805219 (01.12.2018)

210-1

Series S430 and S440 Combines

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

Handle Fluids Safely—Avoid Fires

TS227-UN: 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

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

TM805219 (01.12.2018)

210-05-1

Series S430 and S440 Combines

Safety

Prevent Battery Explosions

TS204-UN: Battery Explosions

Keepsparks,lightedmatches,andopenflameawayfromthetop 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

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

Handle Chemical Products Safely

TS1132-UN: Material Safety Data Sheet

Direct exposure to hazardous chemicals can cause serious injury.

Potentially hazardous chemicals used with John Deere equipmentincludesuchitemsaslubricants,coolants,paints,and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

DX,MSDS,NA-19-19930303

TM805219 (01.12.2018)

210-05-2

Series S430 and S440 Combines

Safety

Handle Starting Fluid Safely

TS1356-UN: Store Safely

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.

DX,FIRE3-19-20140314

Replace worn or damaged hose assemblies immediately with

Avoid High-Pressure John Deere approved replacementFluids 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.

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

X9811-UN: High Pressure

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.

Park Machine SafelyTS230-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

TM805219 (01.12.2018)

210-05-3

Series S430 and S440 Combines

Safety

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

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

Protect Against Noise

TS207-UN: Noise Exposure

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.

DX,NOISE-19-19930303

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

TM805219 (01.12.2018)

210-05-4

Series S430 and S440 Combines

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