John Deere S550, S660, S670, S680, S685, S690 STS Combine Manual TM111919 - PDF

S550, S660, S670, S680, S685, S690 STS Combines Diagnostic Technical Manual

OPERATION AND TEST MANUAL S550, S550 STS, S660, S660 STS, S670 STS, S680 STS, S685 STS, S690 STS TM111919 05 OCT 15 (ENGLISH)

For complete service information also see: S550 STS, S660 STS, S670 STS, S680 STS, S685 STS and S690 STS CombineTM112019 Repair Alternators and Starting MotorsCTM77 PowerTech Plus 4.5L and 6.8L Diesel Engines Level 14 Electronic FuelCTM320 System With Denso HPCR PowerTech 4.5 L and 6.8 L Diesel Engines Level 11 Electronic FuelCTM220 System With Denso HPCR 120 Series Hydraulic CylindersCTM120519 120 Series Hydraulic CylindersCTM114319 PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA TierCTM104 3/Stage III, (Base Engine)

John Deere Agriculture

TM111919-OPERATION AND TEST MANUAL

(g) by Belgreen v2.1

Table of contents FOREWORD Section 210 - GENERAL Group 05 - Safety Group 10 - Combine and Component Identification Group 15 - General Specifications Group 20 - Diagnostic and Testing Procedures Section 211 - DIAGNOSTIC TROUBLE CODES Group 1 - Accessing Diagnostic Codes and Addresses Group 2 - ATC - Diagnostic Trouble Codes Group 3 - AYM - Diagnostic Trouble Codes Group 4 - CAB - Diagnostic Trouble Codes Group 5 - CRU - Diagnostic Trouble Codes Group 6 - CSM - Diagnostic Trouble Codes Group 7 - ECU Levels 21 and 22 - iT4 Engines - Diagnostic Trouble Codes Group 8 - ECU - Non-IT4 Engines - Diagnostic Trouble Codes Group 9 - EIC - Diagnostic Trouble Codes Group 10 - JDL - Diagnostic Trouble Codes Group 11 - LC1 - Diagnostic Trouble Codes Group 12 - LC2 - Diagnostic Trouble Codes Group 13 - MHC - Diagnostic Trouble Codes Group 14 - PDU - Diagnostic Trouble Codes Group 15 - PTP - Diagnostic Trouble Codes Group 16 - RC1 - Diagnostic Trouble Codes Group 17 - RC2 - Diagnostic Trouble Codes Group 18 - SCL - Diagnostic Trouble Codes Group 19 - SDU - Diagnostic Trouble Codes Group 20 - SFC - Diagnostic Trouble Codes Group 21 - SSU - Diagnostic Trouble Codes Group 22 - VCM - Diagnostic Trouble Codes Group 23 - VTi - Diagnostic Trouble Codes Group 24 - XMC - Diagnostic Trouble Codes Group 25 - XSC - Diagnostic Trouble Codes Section 212 - OBSERVABLE SYMPTOMS Group 230 - Fuel, Air Intake, Exhaust, and Cooling Systems Group 240 - Electrical System Group 245 - Electrical Control Units Group 250A - Drives - (S550, S660, S670) Group 250B - Drives - (S680, S685, S685, S690) Group 260A - Steering and Brakes - (S550, S660, S670) Group 260B - Steering and Brakes - (S680, S685, S690) Group 270A - Hydraulic System - (S550, S660, S670) Group 270B - Hydraulic System - (S680, S685, S690) Group 280A - Main Gearcase - (S550, S660, S670) Group 280B - Main Gearcase - (S680, S685, S690) Group 290 - Cab/Open Operator Station Section 220 - ENGINE SYSTEM Group 5 - Engine Systems Section 230 - FUEL, AIR INTAKE, EXHAUST, AND COOLING SYSTEMS Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics Section 239 - FUEL, AIR INTAKE, EXHAUST, AND COOLING SYSTEMS - COMPONENTS <- Go to Global Table of contents

TM111919-OPERATION AND TEST MANUAL

TM111919-OPERATION AND TEST MANUAL

(g) by Belgreen v2.1

Group 05 - Air Intake and Cooling System - Components - Summary of References Group 40A - Air Intake and Cooling System - A Components Group 40B - Air Intake and Cooling System - D Components Group 40C - Air Intake and Cooling System - F Components Group 40D - Air Intake and Cooling System - H Components Group 40E - Air Intake and Cooling System - P Components Group 40F - Air Intake and Cooling System - R Components Group 40G - Air Intake and Cooling System - S Components Group 40H - Air Intake and Cooling System - V Components Section 240 - ELECTRICAL SYSTEM Group 5A - General Information Group 10A - General References Group 10B - Calibration Procedures Group 20A - Theory of Operation - Cab/Operator’s Station Group 20B - Theory of Operation - CAN Bus/Local Link Systems Group 20C - Theory of Operation - Ag Management Solutions Group 20D - Theory of Operation - Lighting Group 20E - Theory of Operation - Engine/Fuel Group 20F - Theory of Operation - Starting/Charging/Power Distribution Group 20G - Theory of Operation - Header Functions Group 20H - Theory of Operation - Feeder House Group 20I - Theory of Operation - Threshing/Separating/Cleaning Group 20J - Theory of Operation - Grain Tank/Unloading Group 20K - Theory of Operation - Residue System Group 20L - Theory of Operation - Transmission/Ground Drive Systems Group 20M - Theory of Operation - Hydraulic Oil/Pressure Group 20N - Theory of Operation - Main Gearcase Group 20O - Theory of Operation - Brakes Group 20P - Theory of Operation - Chassis Group 30A - Schematics - Cab/Operators Station Group 30B - Schematics - CAN Bus/Local Link Systems Group 30C - Schematics - Ag Management Solutions Group 30D - Schematics - Lighting Group 30E - Schematics - Engine/Fuel Group 30F - Schematics - Starting/Charging/Power Distribution Group 30G - Schematics - Header Functions Group 30H - Schematics - Feeder House Group 30I - Schematics - Threshing/Separating/Cleaning Group 30J - Schematics - Grain Tank/Unloading Group 30K - Schematics - Residue System Group 30L - Schematics - Transmission/Ground Drive Systems Group 30M - Schematics - Hydraulic Oil/Pressure Group 30N - Schematics - Main Gearcase Group 30O - Schematics - Brakes Group 30P - Schematics - Chassis Group 50A - Diagnostics - Cab/Operator’s Station Group 50B - Diagnostics - CAN Bus/Local Link Systems Group 50C - Diagnostics - Ag Management Solutions Group 50D - Diagnostics - Lighting Group 50E - Diagnostics - Engine/Fuel Group 50F - Diagnostics - Starting/Charging/Power Distribution Group 50G - Diagnostics - Header Functions Group 50H - Diagnostics - Feeder House

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TM111919-OPERATION AND TEST MANUAL

TM111919-OPERATION AND TEST MANUAL

(g) by Belgreen v2.1

Group 50I - Diagnostics - Threshing/Separating/Cleaning Group 50J - Diagnostics - Grain Tank/Unloading Group 50K - Diagnostics - Residue System Group 50L - Diagnostics - Transmission/Ground Drive Systems Group 50M - Diagnostics - Hydraulic Oil/Pressure Group 50N - Diagnostics - Main Gearcase Group 50O - Diagnostics - Brakes Group 50P - Diagnostics - Chassis Section 245 - ELECTRICAL CONTROL UNITS Group 05 - Electrical Control Units - General Information Group 10A - Accessing Diagnostic Trouble Codes and Addresses Group 10B - Diagnostic Addresses by Control Unit Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics Section 249 - ELECTRICAL CONNECTOR/COMPONENTS Group 05 - Electrical Connector/Components - Summary of References Group 40A - General Information Group 40B - X100 - X149 Group 40C - X150 - X199 Group 40D - X200 - X249 Group 40E - X250 - X299 Group 40F - X300 - X349 Group 40G - X350 - X399 Group 40H - X400 - X449 Group 40I - X450 - X499 Group 40J - X500 - X549 Group 40K - X550 - X599 Group 40L - X600 - X649 Group 40M - X650 - X699 Group 40N - X700 - X749 Group 40O - X750 - X799 Group 40P - X800 - X849 Group 40Q - X850 - X899 Group 40R - X900 - X949 Group 40S - X950 - X999 Group 40T - X1000 - X1049 Group 40U - X4000 - X4999 Group 40V - X5000 - X5999 Group 40W - X8000 - X8999 Group 40X - X9000 - X9999 Section 250A - DRIVES - (S550, S660, S670) Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics Section 250B - DRIVES - (S680, S685, S690) Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics

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TM111919-OPERATION AND TEST MANUAL

TM111919-OPERATION AND TEST MANUAL

(g) by Belgreen v2.1

Section 259 - DRIVES - COMPONENTS Group 05 - Drives - Components - Summary of References Section 260A - STEERING AND BRAKES - (S550, S660, S670) Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics Section 260B - STEERING AND BRAKES - (S680, S685, S690) Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics Section 269 - STEERING AND BRAKES - COMPONENTS Group 05 - Steering and Brakes - Components - Summary of References Section 270A - HYDRAULIC SYSTEM - (S550, S660, S670) Group 10A - Preliminary and Operational Checks Group 10D - Hydraulic Specification Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics Section 270B - HYDRAULIC SYSTEM - (S680, S685, S690) 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, Drives, Steering, Brakes, Main Gearcase - Component Identification - Summary of References Group 40A - Hydraulic - A Components Group 40B - Hydraulic - B Components Group 40C - Hydraulic - C Components Group 40D - Hydraulic - D Components Group 40E - Hydraulic - F Components Group 40F - Hydraulic - G Components Group 40G - Hydraulic - H Components Group 40H - Hydraulic - M Components Group 40I - Hydraulic - O Components Group 40J - Hydraulic - P Components Group 40K - Hydraulic - R Components Group 40L - Hydraulic - S Components Group 40M - Hydraulic - V Components Group 40N - Hydraulic - W Components Group 40O - Hydraulic - X Components Group 40P - Hydraulic - Y Components Section 280A - MAIN GEARCASE - (S550, S660, S670) Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics

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TM111919-OPERATION AND TEST MANUAL

TM111919-OPERATION AND TEST MANUAL

(g) by Belgreen v2.1

Section 280B - MAIN GEARCASE (S680, S685, S690) Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics Section 289 - MAIN GEARCASE - 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 40A - Cab/Open Operator Station Components

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TM111919-OPERATION AND TEST MANUAL

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

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TM111919-OPERATION AND TEST MANUAL

GENERAL

(g) by Belgreen v2.0

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

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

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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Section 210 page 1

TM111919-OPERATION AND TEST MANUAL

TM111919-OPERATION AND TEST MANUAL

(g) by Belgreen v2.1

Section 210 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 1 Prepare for Emergencies ...................................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 2 Prevent Acid Burns ............................................................................................................................... 3 Handle Chemical Products Safely ......................................................................................................... 3 Handle Starting Fluid Safely ................................................................................................................. 4 Avoid High-Pressure Fluids ................................................................................................................... 4 Park Machine Safely ............................................................................................................................. 5 Support Machine Properly .................................................................................................................... 6 Wear Protective Clothing ...................................................................................................................... 7 Protect Against Noise ........................................................................................................................... 7 Work in Clean Area ............................................................................................................................... 8 Work In Ventilated Area ........................................................................................................................ 8 Illuminate Work Area Safely ................................................................................................................. 8 Service Machines Safely ....................................................................................................................... 9 Construct Dealer-Made Tools Safely ..................................................................................................... 9 Service Cooling System Safely ........................................................................................................... 10 Service Accumulator Systems Safely .................................................................................................. 10 Wait Before Opening High-Pressure Fuel System ............................................................................... 11 Replace Safety Signs .......................................................................................................................... 11 Use Proper Lifting Equipment ............................................................................................................. 12 Remove Paint Before Welding or Heating ........................................................................................... 12 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 14 Service Tires Safely ............................................................................................................................ 15 Avoid Harmful Asbestos Dust ............................................................................................................. 15 Practice Safe Maintenance ................................................................................................................. 17 Use Proper Tools ................................................................................................................................. 17 Decommissioning: Proper Recycling and Disposal of Fluids and Components ................................... 18 Live With Safety ................................................................................................................................. 19 Group 10 - Combine and Component Identification ......................................................................... 20 Identification Numbers ....................................................................................................................... 20 Machine Identification Plate ............................................................................................................... 20 Machine Identification Plate Location ................................................................................................. 21 Engine Serial Number (Tier 2/Stage II) ............................................................................................... 22 Engine Serial Number (Interim Tier 4/Stage III B) ............................................................................... 22 Hydrostatic Drive Unit Pump (ProDrive Machines) .............................................................................. 22 Hydrostatic Drive Unit Motor (ProDrive Machines) ............................................................................. 23 Two-Speed Four-Wheel Drive Motor ................................................................................................... 23 Engine Gearcase (ProDrive Machines) ................................................................................................ 23 Rotor Drive Gearcase ......................................................................................................................... 24 Transmission (ProDrive Machines) ...................................................................................................... 24 Feeder House Reverser ...................................................................................................................... 24 Multi-Speed Feeder House Gearcase (If Equipped) ............................................................................. 25 Chopper (If Equipped) ......................................................................................................................... 25 Chopper Tailboard (Deluxe Residue Evacuation System) ................................................................... 25 Chopper Tailboard (Premium Residue Evacuation System) ................................................................ 26 Power Tailboard (Deluxe Residue Evacuation System) ....................................................................... 26 Spreader (Deluxe Residue Evacuation System) .................................................................................. 26

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TM111919-OPERATION AND TEST MANUAL

TM111919-OPERATION AND TEST MANUAL

(g) by Belgreen v2.1

Hydraulic Designators ........................................................................................................................ 27 Hydraulic Circuit Symbols ................................................................................................................... 28 Group 15 - General Specifications ....................................................................................................... 29 Operating Speeds - S550 .................................................................................................................... 29 Operating Speeds - S660 .................................................................................................................... 31 Operating Speeds - S670 .................................................................................................................... 33 Operating Speeds - S680, S685, S690 ................................................................................................ 35 Specifications - S550 .......................................................................................................................... 37 Specifications - S660 .......................................................................................................................... 39 Specifications - S670 .......................................................................................................................... 42 Specifications - S680, S685, S690 ...................................................................................................... 45 Dimensions (Grain Tank Extensions) - S550 ....................................................................................... 48 Dimensions (Grain Tank Extensions) - S660 ....................................................................................... 49 Dimensions (Grain Tank Extensions) - S670 ....................................................................................... 50 Dimensions (Grain Tank Extensions) - S680, S685, S690 ................................................................... 51 Dimension Reference Points (Grain Tank Extensions) - S550 ............................................................. 52 Dimension Reference Points (Grain Tank Extensions) - S660 ............................................................. 53 Dimension Reference Points (Grain Tank Extensions) - S670 ............................................................. 54 Dimension Reference Points (Grain Tank Extensions) - S680, S685, S690 ......................................... 55 Dimensions (Grain Tank Covers) - S550 ............................................................................................. 55 Dimensions (Grain Tank Covers) - S660 ............................................................................................. 56 Dimensions (Grain Tank Covers) - S670 ............................................................................................. 57 Dimensions (Grain Tank Covers) - S680, S685, S690 ......................................................................... 58 Dimension Reference Points (Grain Tank Covers) - S550 ................................................................... 58 Dimension Reference Points (Grain Tank Covers) - S660 ................................................................... 59 Dimension Reference Points (Grain Tank Covers) - S670 ................................................................... 60 Dimension Reference Points (Grain Tank Covers) - S680, S685, S690 ............................................... 61 Unified Inch Bolt and Screw Torque Values ........................................................................................ 62 Metric Bolt and Screw Torque Values ................................................................................................. 63 Group 20 - Diagnostic and Testing Procedures ................................................................................ 64 Troubleshooting .................................................................................................................................. 64

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TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Group 05 - Safety Recognize Safety Information

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.

Handle Fluids Safely—Avoid Fires

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.

Prepare for Emergencies

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Section 210 page 1

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

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.

Prevent Battery Explosions

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).

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Section 210 page 2

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Prevent Acid Burns

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: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: 1.Flush your skin with water.

2.Apply baking soda or lime to help neutralize the acid.

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

If acid is swallowed: 1.Do not induce vomiting.

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

3.Get medical attention immediately.

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Section 210 page 3

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Handle Chemical Products Safely

Material Safety Data Sheet Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, 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.)

Handle Starting Fluid Safely

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.

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Section 210 page 4

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Avoid High-Pressure Fluids

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

Replace worn or damaged hose assemblies immediately with 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.

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.

Park Machine Safely

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 in operator station. <- Go to Section TOC

Section 210 page 5

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Support Machine Properly

Support Properly Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or 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.

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Section 210 page 6

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Wear Protective Clothing

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.

Protect Against Noise

Noise Exposure

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Section 210 page 7

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

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.

Work in Clean Area

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.

Work In Ventilated Area

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.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Illuminate Work Area Safely

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Section 210 page 8

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

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.

Service Machines Safely

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.

Construct Dealer-Made Tools Safely

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Section 210 page 9

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

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.

Service Cooling System Safely

Cooling System Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Service Accumulator Systems Safely

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Section 210 page 10

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Hydraulic Accumulator Escaping fluid or gas from systems with pressurized accumulators that are used in air conditioning, hydraulic, and air brake 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 pressurized system before removing accumulator.

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.

Wait Before Opening High-Pressure Fuel System

High-Pressure Fuel Lines High-pressure fluid remaining in fuel lines can cause serious 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.

Replace Safety Signs

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Section 210 page 11

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

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

Use Proper Lifting Equipment

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.

Remove Paint Before Welding or Heating

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Section 210 page 12

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Toxic Fumes Avoid potentially toxic fumes and dust.

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

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.

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

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

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Section 210 page 13

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray Flammable spray can be generated by heating near pressurized 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.

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Section 210 page 14

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Service Tires Safely

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

Do not attempt to mount a tire unless you have the proper 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.

When inflating tires, use a clip-on chuck and extension hose long 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.

Avoid Harmful Asbestos Dust

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Section 210 page 15

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

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 some gaskets. The asbestos used in these components is usually 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.

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Section 210 page 16

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 05: Safety

Practice Safe Maintenance

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 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.

Use Proper Tools

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Section 210 - GENERAL

Group 05: Safety

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.

Decommissioning: Proper Recycling and Disposal of Fluids and Components

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.

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Section 210 - GENERAL

Group 10: Combine and Component Identification

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.

Live With Safety

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

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Section 210 - GENERAL

Group 10: Combine and Component Identification

Group 10 - Combine and Component Identification Identification Numbers Your machine has these various identification plates. The letters and numbers stamped on these plates identify a component or assembly. ALL of these characters are needed when ordering parts or identifying a machine or component for any John Deere 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 each of the following photographs.

Machine Identification Plate →NOTE:

Sample Identification Plate

Sample Identification Plate

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TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 10: Combine and Component Identification

Sample Identification Plate

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

Machine Identification Plate Location

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TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 10: Combine and Component Identification

Machine Identification Plate Location Located on right side of cab handrail landing.

Engine Serial Number (Tier 2/Stage II)

Engine Serial Number Identification Plate Location Located on front side of engine above starter.

Engine Serial Number (Interim Tier 4/Stage III B)

Engine Serial Number Identification Plate Location Located on front side of engine above starter.

Hydrostatic Drive Unit Pump (ProDrive Machines)

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TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 10: Combine and Component Identification

Hydrostatic Drive Unit Pump Identification Plate Location Located on top of hydrostatic drive pump.

Hydrostatic Drive Unit Motor (ProDrive Machines)

Hydrostatic Drive Unit Motor Identification Plate Location Located on bottom side of hydrostatic drive motor.

Two-Speed Four-Wheel Drive Motor

Two-Speed Four-Wheel Drive Motor Identification Plate Location Located on top side of four-wheel drive motor.

Engine Gearcase (ProDrive Machines)

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TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 10: Combine and Component Identification

Engine Gearcase Identification Plate Location Located on rear side of engine gearcase.

Rotor Drive Gearcase

Rotor Drive Gearcase Identification Plate Location Located on left side of rotor drive gearcase.

Transmission (ProDrive Machines)

Transmission Identification Plate Location Located on front of transmission.

Feeder House Reverser

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TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 10: Combine and Component Identification

Feeder House Reverser Identification Plate Location Located on top side of feeder house reverser.

Multi-Speed Feeder House Gearcase (If Equipped)

Multi-Speed Feeder House Gearcase, Identification Plate Location Located on rear side of multi-speed feeder house gearcase.

Chopper (If Equipped)

Chopper Identification Plate Location Located on left side of chopper.

Chopper Tailboard (Deluxe Residue Evacuation System)

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TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 10: Combine and Component Identification

Chopper Tailboard Identification Plate Location Located on left side of chopper tailboard.

Chopper Tailboard (Premium Residue Evacuation System)

Chopper Tailboard Identification Plate Location Located on left side of chopper tailboard.

Power Tailboard (Deluxe Residue Evacuation System)

Power Tailboard Identification Plate Location Located on left side of power tailboard.

Spreader (Deluxe Residue Evacuation System)

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Section 210 - GENERAL

Group 10: Combine and Component Identification

Spreader Identification Plate Location Located on right side of the spreader.

Hydraulic Designators

The hydraulic designators are used to identify components on hydraulic schematics in this manual. In the legend, the designators are shown in alphanumeric order with a brief description. In the component identification group, designator used in conjunction with a description and photograph or image.

The hydraulic designators begin with a letter that describes the device: DEFINITIONS: A Accumulator BSensor or Gauge CCylinder, Actuator, or Piston DCheck Valve F Filter GValve Block, Assembly, or Gearcase H Cooler JMiscellaneous Component M Motor O Orifice P Pump RReservoir or Tank S Switch V Valve WMechanical Assembly XDiagnostic Receptacle or Coupler YSolenoid Valve ZPort with Plug

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Section 210 - GENERAL

Group 15: General Specifications

Hydraulic Circuit Symbols

Hydraulic Circuit Symbols

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Section 210 - GENERAL

Group 15: General Specifications

Group 15 - General Specifications Operating Speeds - S550 Speeds shown are average and can vary from machine to machine. →NOTE: Operating speed specifications and design subject to change without notice.

Engine Speeds Engine Speeds Slow Idle (Separator Off)

1300

Mid Speed (Separator Off)

rpm

Fast Idle (Separator Off)

1850

Full Load Rated Speed

rpm 2550

Separator Drive Shaft Speed

rpm

Separator Drive Shaft Speed

1457 rpm

2400 rpm

Main Countershaft Speed

1457 rpm

Main Countershaft Speed

Single Tine Separator Speeds Separator Speeds High Range

450—1210

Low Range

rpm 220—560

Feeder House Lower Shaft Sprocket Speeds

rpm

Feeder House Lower Shaft Speeds Standard Variable Speed

490—750

Heavy Duty Variable Speed

rpm

Fixed Speed

750 rpm 490

490—

rpm

Feed Accelerator Speeds Feed Accelerator Speeds Feed Accelerator (Standard Speed)

430/780

Feed Accelerator (Optional Slow Speed)

rpm 310/770

Discharge Beater Speeds

rpm

797 rpm

Discharge Beater Speed

Jackshaft Speeds Jackshaft Speeds Front

Right

520

Jackshaft

Rear

rpm

Right Jackshaft

520

Cleaning Fan Speeds

rpm

Cleaning Fan Speeds Standard Speed

620—1200

Special Slow Speed

rpm

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250—

500 rpm Section 210 page 29

TM111919-OPERATION AND TEST MANUAL

Section 210 - GENERAL

Group 15: General Specifications

Elevator Speeds Elevator Speeds Clean Grain Elevator

386

Clean Grain Loading Auger

rpm

Tailings Elevator, Lower Auger

415

Tailings Elevator, Upper Auger

rpm

Shoe Drive

395

Conveyor Augers

rpm 625

Unloading System Speeds

rpm

Unloading System Speeds (Separator Engaged)

298

Unloading System Countershaft

rpm

1005 rpm

Unloading Auger Gearbox, Input Shaft

420

435 rpm

Unloading Vertical Auger

rpm

435 rpm

Unloading Outer Auger

435 rpm

Grain Tank Horizontal Augers (Front and Rear)

410 rpm

Chopper Speeds Chopper Speeds Chopper/Discharge

Beater

1880 rpm

Jackshaft Chopper (Two Speeds)

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1505/2345 rpm

Section 210 page 30

TM111919-OPERATION AND TEST MANUAL

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