JOHN DEERE S785 COMBINES (TM140719) SERVICE MANUAL

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

DIAGNOSTIC TECHNICAL MANUAL S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines TM140719 01DEC18 (ENGLISH)

For complette service information also see: S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combine Repair..............................................tm140819

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.

TM140719 (01.12.2018)

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

Contents Section 230 - Fuel, Air Intake, Exhaust, and

Section 210 - General

Group 05 - Safety Cooling Systems Group 10 - Combine and Component IdentificationGroup 20 - Theory of Operation Group 15 - General SpecificationsGroup 30 - Schematics Group 20 - Diagnostic and Testing ProceduresGroup 50 - Diagnostics

Section 211 - Diagnostic Trouble Codes

Section 239 - Air Intake and Cooling System - Components

Group 1 - Accessing Diagnostic Codes and Addresses Group 05 - Air Intake and Cooling System Group 2 - AIC - Diagnostic Trouble CodesComponents - Summary of References Group 3 - ATC - Diagnostic Trouble CodesGroup40A-AirIntakeandCoolingSystem-A Group 4 - AYM - Diagnostic Trouble CodesComponents Group 5 - CAB - Diagnostic Trouble CodesGroup40B-AirIntakeandCoolingSystem-D Group 6 - CLC - Diagnostic Trouble CodesComponents Group 7 - CRU - Diagnostic Trouble CodesGroup40C-AirIntakeandCoolingSystem-F Group 8 - CSM - Diagnostic Trouble CodesComponents Group 9 - ECU - T2, T3 and iT4 Engines - Diagnostic Group 40D - Air Intake and Cooling System - H Trouble CodesComponents Group 10 - ECU Final Tier 4 - 9.0L Diagnostic Trouble Group 40E - Air Intake and Cooling System - P Codes Components Group 11 - ECU Final Tier 4 - 13.5L Diagnostic Trouble Group 40F - Air Intake and Cooling System - R Codes Components Group 12 - EIC - Diagnostic Trouble CodesGroup40G-AirIntakeandCoolingSystem-S Group 13 - GLM - Diagnostic Trouble CodesComponents Group 14 - GQM - Diagnostic Trouble CodesGroup40H-AirIntakeandCoolingSystem-V Group 15 - GR6 - Diagnostic Trouble CodesComponents Group 16 - HIM - Diagnostic Trouble CodesGroup40I-AirIntakeandCoolingSystem-X Group 17 - IR6 - Diagnostic Trouble CodesComponents Group 18 - JDL - Diagnostic Trouble CodesGroup40J-AirIntakeandCoolingSystem-Y Group 19 - LC1 - Diagnostic Trouble CodesComponents Group 20 - LC2 - Diagnostic Trouble Codes Group 21 - MHC - Diagnostic Trouble Codes

Section 240 - Electrical System

Group 22 - OIC - Diagnostic Trouble Codes Group 5A - General Information Group 23 - PDU - Diagnostic Trouble Codes Group 10A - Calibration Procedures Group 24 - PTP - Diagnostic Trouble Codes Group 25 - RC1 - Diagnostic Trouble Codes Station Group 26 - RC2 - Diagnostic Trouble Codes Group 27 - SCL - Diagnostic Trouble Codes Systems Group 28 - SSU - Diagnostic Trouble Codes Group 29 - VTi - Diagnostic Trouble Codes Solutions Group 30 - VTV - Diagnostic Trouble Codes Group 20D - Theory of Operation - Lighting Group 31 - XMC - Diagnostic Trouble Codes Group 20E - Theory of Operation - Engine/Fuel Group 32 - XSC - Diagnostic Trouble Codes Power Distribution

Group 20A - Theory of Operation - Cab/Operator`s Group 20B - Theory of Operation - CAN Bus/Local Link Group 20C - Theory of Operation - Ag Management

Group 20F - Theory of Operation - Starting/Charging/

Section 212 - Observable SymptomsGroup20G-TheoryofOperation-Header

Group 230 - Fuel, Air Intake, Exhaust, and Cooling Functions SystemsGroup 20H - Theory of Operation - Feeder House Group 240 - Electrical SystemGroup20I-TheoryofOperation-Threshing/ Group 245 - Electrical Control UnitsSeparating/Cleaning Group 250A - Drives - ( S760, S770)Group20J-TheoryofOperation-GrainTank/ Group 250B - Drives - (S780, S785, S790)Unloading Group 260A - Steering and Brakes - ( S760, S770)Group20K-TheoryofOperation-Residue Group 260B - Steering and Brakes - (S780, S785, System S790) Group 20L - Theory of Operation - Transmission/ Group 270A - Hydraulic System - (S760, S770)Ground Drive Systems Group 270B - Hydraulic System - (S780, S785, Group 20M - Theory of Operation - Hydraulic Oil/Air S790) Compressor Group 280A - Main Gear Case - (S760, S770)Group 20N - Theory of Operation - Main Gearcase Group280B-MainGearCase-(S780,S785,Group 20O - Theory of Operation - Brakes S790)Group 20P - Theory of Operation - Chassis Group 290 - Cab/Open Operator StationGroup 30A - Schematics - Cab/Operators Station Group 30B - Schematics - CAN Bus/Local Link

Section 220 - Engine SystemSystems TM140719 (01.12.2018)

S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines Group 5 - Engine SystemsGroup30C-Schematics-AgManagement

Group 30D - Schematics - LightingGroup RC1 - RC1 - Diagnostic Addresses Group 30E - Schematics - Engine/FuelGroup RC2 - RC2 - Diagnostic Addresses Group30F-Schematics-Starting/Charging/PowerGroup SSU - SSU - Diagnostic Addresses DistributionGroup VTI - VTi - Diagnostic Addresses Group 30G - Schematics - Header FunctionsGroup VTV - VTv - Diagnostic Addresses Group 30H - Schematics - Feeder HouseGroup XMC - XMC - Diagnostic Addresses Group30I-Schematics-Threshing/Separating/Group XSC - XSC - Diagnostic Addresses Cleaning

Group 30J - Schematics - Grain Tank/UnloadingSection249-ElectricalConnector/ Group 30K - Schematics - Residue SystemComponents

Group 30L - Schematics - Transmission/Ground Drive Group 05 - Electrical Connector/Components SystemsSummary of References Group30M-Schematics-HydraulicOil/AirGroup 40 - General Information CompressorGroup 40A - XA - Electrical Assemblies Group 30N - Schematics - Main Gear CaseGroup 40B - XB - Sensors Group 30O - Schematics - BrakesGroup 40E - XE - Lights Group 30P - Schematics - ChassisGroup 40F - XF - Fuses Group 50A - Diagnostics - Cab/Operator`s StationGroup 40G - XG - Charging Group50B-Diagnostics-CANBus/LocalLinkGroup 40H - XH - Monitoring Devices SystemsGroup 40K - XK - Relays Group50C-Diagnostics-AgManagementGroup 40M - XM - Motors SolutionsGroup 40R - XR - Resistors Group 50D - Diagnostics - LightingGroup 40S - XS - Switches Group 50E - Diagnostics - Engine/FuelGroup 40V - XD - Diodes Group 50F - Diagnostics - Starting/Charging/Power Group 40X - XX/GND - Interconnects and Ground Distribution Points Group 50G - Diagnostics - Header FunctionsGroup40Y-XY-ElectronicallyActuatedMechanical Group 50H - Diagnostics - Feeder HouseDevices Group 50I - Diagnostics - Threshing/Separating/ Cleaning

Section 250A - Drives - (S760, S770)

Group 50J - Diagnostics - Grain Tank/UnloadingGroup 10A - Preliminary & Operational Checks Group 50K - Diagnostics - Residue SystemGroup 10D - Hydraulic Specifications Group50L-Diagnostics-Transmission/GroundDriveGroup 20 - Theory of Operation SystemsGroup 30 - Schematics Group 50M - Diagnostics - Hydraulic Oil/PressureGroup 50 - Diagnostics Group 50N - Diagnostics - Main Gear Case Group 50O - Diagnostics - Brakes

Section 250B - Drives - (S780, S785, S790) Group 50P - Diagnostics - Chassis Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications

Section 245 - Electrical Control UnitsGroup 20 - Theory of Operation Group 05 - General InformationGroup 30 - Schematics Group10A-AccessingDiagnosticTroubleCodesandGroup 50 - Diagnostics Addresses Group 20 - Theory of Operation

Section 259 - Drives - Components Group 30 - Schematics

Group 50 - Diagnostics References Group AIC - AIC - Diagnostic Addresses Group ATC - ATC - Diagnostic Addresses

Group 05 - Drives - Components - Summary of

Section 260A - Steering and Brakes - (S760, Group AYM - AYM - Diagnostic Addresses

S770)

Group CAB - CAB - Diagnostic Addresses Group 10A - Preliminary & Operational Checks Group CLC - CLC - Diagnostic Addresses Group 10D - Hydraulic Specifications Group CRU - CRU - Diagnostic Addresses Group 20 - Theory of Operation Group CSM - CSM - Diagnostic Addresses Group 30 - Schematics Group ECU - ECU - Diagnostic Addresses Group 50 - Diagnostics Group EIC - EIC - Diagnostic Addresses Group GLM - GLM - Diagnostic Addresses

Section 260B - Steering and Brakes - (S780, Group GQM - GQM - Diagnostic Addresses

Group GR6 - GR6 - Diagnostic AddressesS785, S790)

Group HIM - HIM - Diagnostic AddressesGroup 10A - Preliminary & Operational Checks Group IR6 - IR6 - Diagnostic AddressesGroup 10D - Hydraulic Specifications Group JDL - JDL - Diagnostic AddressesGroup 20 - Theory of Operation Group LC1 - LC1 - Diagnostic AddressesGroup 30 - Schematics Group LC2 - LC2 - Diagnostic AddressesGroup 50 - Diagnostics Group MHC - MHC - Diagnostic Addresses

Group OIC - OIC - Diagnostic AddressesSection269-SteeringandBrakesGroupTM140719 PDU - PDU - Diagnostic AddressesComponents (01.12.2018) S760 STS™, S770 STS™, S780 STS™, S785 STS™, and S790 STS™ Combines

Group 40X - Diagnostic Receptacle or Coupler Group 40Y - Solenoid Valve

Summary of References

Section 270A - Hydraulic System - (S760, S770)

Section 280A - Main Gear Case - (S760, S770)

Group 10A - Preliminary and Operational Checks Group 10D - Hydraulic Specification Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics

Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics

Section 270B - Hydraulic System - (S780, S785, S790)

Section 280B - Main Gear Case (S780, S785, S790)

Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics

Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics

Section 279 - Hydraulic - Components Group 05 - Hydraulic - Components - Summary of References Group 40A - Accumulator Group 40B - Sensor or Gauge Group 40C - Cylinder, Actuator, or Piston Group 40D - Check Valve Group 40F - Filter Group 40G - Valve Block, Assembly, or Gear Case Group 40H - Cooler Group 40M - Motor Group 40O - Orifice Group 40P - Pump Group 40R - Reservoir or Tank Group 40S - Switch Group 40V - Valve Group 40W - Mechanical Assembly

TM140719 (01.12.2018)

Section 289 - Main Gear Case - Components Group 05 - Main Gearcase - Components - Summary of References

Section 290 - Cab/Open Operator`s Station Group 10D - Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics

Section 299 - Cab/Open Operator`s Station Components

Group 05 - Components - Summary of Reference Group 40A - Cab/Open Operator Station Components

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

Section 210 Contents

General Page

Page

Group 05 - Safety Recognize Safety Information...............................210-05-1 Follow Safety Instructions......................................210-05-1 Service Tires Safely...............................................210-05-1 Understand Signal Words......................................210-05-2 Remove Paint Before Welding or Heating.............210-05-2 Handle Fluids Safely-Avoid Fires..........................210-05-2 Prevent Battery Explosions...................................210-05-3 Handling Batteries Safely......................................210-05-3 Prepare for Emergencies.......................................210-05-4 Prevent Acid Burns................................................210-05-4 Avoid High-Pressure Fluids...................................210-05-4 Service Accumulator Systems Safely....................210-05-5 Wait Before Opening High-Pressure Fuel 210-05-5 System...........................................................

Park Machine Safely..............................................210-05-5 Support Machine Properly.....................................210-05-5

Identification Numbers...........................................210-10-1 Machine Identification Plate..................................210-10-1 Machine Identification Plate Location....................210-10-1 Engine Serial Number...........................................210-10-2 Hydrostatic Drive Unit Pump (ProDrive 210-10-2 Machines).......................................................

Hydrostatic Drive Unit Motor (ProDrive 210-10-2 Machines).......................................................

Engine Gearcase (ProDrive Machines).................210-10-2 Rotor Drive Gearcase............................................210-10-3 Transmission (ProDrive Machines).......................210-10-3 Feeder House Reverser........................................210-10-3 Multi-Speed Feeder House Gearcase (If 210-10-3 Equipped).......................................................

Chopper (If Equipped)...........................................210-10-4 Chopper Tailboard.................................................210-10-4 Advanced PowerCast Chopper Tailboard.............210-10-4

Wear Protective Clothing.......................................210-05-6 Service Machines Safely.......................................210-05-6 Work In Ventilated Area.........................................210-05-6 Illuminate Work Area Safely..................................210-05-6

Power Tailboard.....................................................210-10-4 Spreader................................................................ 210-10-5

Replace Safety Signs............................................210-05-7 Use Proper Lifting Equipment................................210-05-7 Avoid Harmful Asbestos Dust................................210-05-7 Work in Clean Area...............................................210-05-7

Group 15 - General Specifications Operating Speeds (S760 and S770).....................210-15-1 Operating Speeds (S780, S785, S790).................210-15-2

Practice Safe Maintenance....................................210-05-8 Use Proper Tools...................................................210-05-8 Construct Dealer-Made Tools Safely.....................210-05-8 Avoid Heating Near Pressurized Fluid Lines.........210-05-9 Decommissioning - Proper Recycling and Disposal 210-05-9 of Fluids and Components.............................

Use Adequate Service Facilities............................210-05-9 Live With Safety.....................................................210-05-10 Servicing Electronic Control Units.........................210-05-10 Welding Near Electronic Control Units..................210-05-10 Precautions for Welding........................................210-05-10 Clean Exhaust Filter Safely...................................210-05-11 Avoid Static Electricity Risk When Refueling.........210-05-12

Hydraulic Designators...........................................210-10-5 Hydraulic Circuit Symbols.....................................210-10-6

Specifications (S760 and S770)............................210-15-3 Specifications (S780, and S790)...........................210-15-5 Dimensions (S760 and S770)...............................210-15-7 Dimensions (S770 HillMaster™)...........................210-15-7 Dimensions (S780, S785, and S790)....................210-15-8 Dimensions(S780HillMaster™,S785HillMaster™ 210-15-8 and S790 HillMaster™)..................................

Dimension Reference Points.................................210-15-9 CARB Non-road Emissions Control Warranty 210-15-10 Statement-Compression Ignition....................

EPA Non-road Emissions Control Warranty 210-15-16 Statement-Compression Ignition....................

Unified Inch Bolt and Screw Torque Values..........210-15-17 Metric Bolt and Screw Torque Values....................210-15-18 Group 20 - Diagnostic and Testing Procedures Troubleshooting..................................................... 210-20-1

Group 10 - Combine and Component Identification

TM140719 (01.12.2018)

210-1

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 isnot 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.

TS201-UN: Safety Messagesassistance, contact your John Deere dealer.

If you do not understand any part of this manual and need DX,READ-19-20090616

Service Tires SafelyDonotattempttomountatireunlessyouhavetheproper equipment and experience to perform the job.

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

deform the wheel.

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.

TM140719 (01.12.2018)

210-05-1

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 before heating: 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.

place.

TS220-UN: Toxic Fumes

Avoid potentially toxic fumes and dust.

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

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

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

TM140719 (01.12.2018)

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

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 aftertohandling.

DX,WW,BATTERIES-19-20101202

TM140719 (01.12.2018)

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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 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.

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.

TM140719 (01.12.2018)

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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

TM140719 (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

TM140719 (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 brakepads, brakebandandlining 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

TM140719 (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.

For loosening and tightening hardware, use the correct size tools.

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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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 inotherthanspeciallydesignedincineratorsmaybe 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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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

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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.

Clean Exhaust Filter Safely

TS1695-UN: Stop

TS227-UN: Fire Safety

During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common materials.

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.

TS271-UN: Hand Over Flame

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.

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 TS1693-UN: Moving Parts

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 leaving the operator’s station.

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Safety Shut off engine and remove key (if equipped) before leaving the DX,EXHAUST,FILTER-19-20110112 machine unattended.

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.

grounding and bonding practices.

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 DX,FUEL,STATIC,ELEC-19-20130712

RG22142-UN: Explosion

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Combine and Component Identification

Group 10 Combine and Component Identification product support program. Also, they are needed for law enforcement to trace your machine if it is ever stolen.

ACCURATELY record these characters in the spaces provided in Your machine has these various identification plates. The letters each of the following photographs. and numbers stamped on these plates identify a component or FM44310,0000AED-19-20121018 assembly. ALL of these characters are needed when ordering parts or identifying a machine or component for any John Deere

Identification Numbers

Machine Identification Plate NOTE:

H101201-UN: Sample Identification Plate

H95295-UN: Sample Identification Plate

H101237-UN: Sample Identification Plate

H101238-UN: Sample Identification Plate

Machine identification plate varies depending on where machine is shipped. Locate identification plate on machine and compare with information shown here.

FM44310,0000AEE-19-20110505

Machine Identification Plate Location

H97568-UN: Machine Identification Plate Location

Located on right side of cab handrail landing.

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Combine and Component Identification FM44310,0000AEF-19-20110505

Engine Serial Number

H99415-UN: S780, S785 and S790

S760 and S770: located on rear side of engine.

S780, S785 and S790: located on front side of engine above starter.

H99414-UN: S760 and S770

RW67285,0002D4C-19-20170621

Hydrostatic Drive Unit Pump (ProDrive Machines)

H99425-UN:on Hydrostatic Unit Pump Identification Plate Location Located top ofDrive hydrostatic drive pump.

FM44310,0000AF2-19-20110505

Hydrostatic Drive Unit Motor Identification Plate Location Hydrostatic Drive Unit Motor (ProDrive H99424-UN: Located on bottom side of hydrostatic drive motor.

Machines) FM44310,0000AF3-19-20110505

Engine Gearcase (ProDrive Machines)

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