John Deere 6650, 6750, 6850, 6950 Self Harvester Diagnosis & Test Manual TM4631 PDF

6650, 6750, 6850 and 6950 Self-Propelled Forage Harvesters (SN. from 504341-)

DIAGNOSIS AND TESTS MANUAL Self-Propelled Forage Harvesters models 6650, 6750, 6850, 6950 (SN: 504341-) TM4631 01 SEP 05 (ENGLISH)

For complete service information also see: 686 and 688 Rotary Harvesting Units

TM4585

630, 630A, 645 and 645A Pickup Platforms and 664, 665R, 666 and 666R Row-Crop Headers

TM4530

676 Rotary Harvesting Unit

TM4528

PowerTech 8.1 L Diesel Engines Base Engine

CTM86

Alternators and Starting Motors

CTM77

Electronic Fuel Injection Systems

CTM68

Machine Connection Information

CTM441

Cam Lobe Motors

CTM19

PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic Fuel Systems with Bosch In-Line Pump)

CTM134

PowerTech 10.5L and 12.5L, 6105 and 6125 Diesel Engines (With Lucas Engine Controllers, Level 6, Electronic Fuel System), Op & Test

CTM115

PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)

CTM104

PowerTech 10.5 L & 12.5 L Diesel Base Engine

CTM100

John Deere Agriculture Pinted by Belgreen

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD Section 05 - SAFETY Group 05 - Safety Information Section 10 - GENERAL INFORMATION Group 05 - Fuel, Lubricants and Coolant Group 10 - Torque Values Group 15 - Serial Numbers Group 20 - Dimensions Section 20 - ENGINE Group 05 - Engine Removal and Installation Section 30 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 05 - Fuel Tank Group 10 - Air Intake System Group 15 - Engine Cooling System Section 40 - ELECTRICAL SYSTEM Group 05 - Electrical Connectors Group 10 - Electrical System Components Section 50 - POWER TRAIN Group 05 - Main Drive Belt Replacement Group 10 - Bevel Gear Drive Group 15 - Transmission and Differential Group 20 - Final Drives Group 25 - Hydrostatic Drive, Variable Pump Group 30 - Hydrostatic Drive, Fixed-Displacement Motor Group 35 - Hydrostatic Drive, Oil Change Group 40 - Cam Lobe Motor Section 60 - BRAKES, STEERING AND REAR AXLE Group 05 - Brake Operation Group 10 - Brakes Group 15 - Hydrostatic Steering Group 16 - ROW-TRAK System Group 20 - Rear Axle Section 70 - HYDRAULIC SYSTEM Group 05 - Hydraulic Pressure Accumulator Group 10 - Triple Hydraulic Pump Group 15 - Electromagnetic Control Valve Group 20 - Reverser Motor Group 25 - Hydraulic Motor - Discharge Spout Section 80 - MISCELLANEOUS Group 05 - Fuel Tank Hood Group 10 - Central Lubrication System Section 90 - OPERATOR′S CAB, AIR CONDITIONING SYSTEM Group 05 - Control Levers Group 10 - Cab Ventilation Group 15 - Cab Window Replacement Group 20 - R134a Air Conditioning System Group 25 - Super Comfort Seat Section 100 - HARVESTING UNITS Group 05 - Harvesting Unit Cross Drive Group 10 - Harvesting Units Section 110 - FEEDING SYSTEM Group 05 - Length-of-Cut Transmission <- Go to Global Table of contents

tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 10 - Reverser Motor and Clutch Group 15 - Electric Clutch Group 20 - Feed Roll Channel Group 25 - Feed Roll Assembly Group 30 - Locking Pawl Section 120 - CUTTERHEAD ASSEMBLY Group 05 - Knife Sharpening Device Group 10 - Cutterhead Group 15 - Bottom and Outlet Bands Group 20 - Stationary Knife Removal and Installation Group 25 - Kernel Processor Group 30 - Power Chute Section 130 - DISCHARGE COMPONENTS Group 05 - Discharge Fan Group 10 - Blower Rotor and Rotor Bearings Group 15 - Discharge Spout Section 210 - GENERAL INFORMATION Group 05 - Specifications Group 10 - Drive Diagrams Group 15 - Ballast Charts Group 20 - Tread Widths Section 211 - SERVICE CODES Group Cont - Control Unit Group ECU - Diagnostic Trouble Codes for Powertech Engine 6081 Group ECU - Diagnostic Trouble Codes for Powertech Engine 6125 Group ECU - ECU Service Codes (Cummins Engine) Section 220 - ENGINE Group 05 - Engine Specifications Group 10 - Engine Tests Section 230 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 05 - Fuel, Air Intake and Cooling Systems Section 240 - ELECTRICAL SYSTEM (UP TO SERIAL NO. 504991) Group 05 - Preliminary Checks Group 06 - General Information Group 07 - Test Equipment Group 10 - Electrical System Diagrams Group 15A - Batteries, Starting Motor, Alternator Group 15B - Safety Switches, Basic Relays Group 15C - Engine Shut-Off Device Group 15D - Gauges Group 15E - Electronic INFO-TRAK Monitor Group 15H - Turn Discharge Spout Group 15I - Raise/Lower Discharge Spout Group 15K - Central Lubrication System Group 15L - Horizontal Reel Adjustment Group 15M - Raise Reel Group 15N - Reel Speed Adjustment Group 15O - 676 Rotary Harvesting Unit (North America) Group 15P - Attach Trailer Group 15Q - Header Raise/Lower Group 15R - Pressure Valves, Trailer Dump Group 15S - Main Clutch, Reverser Group 15T - Four-Wheel Drive <- Go to Global Table of contents

tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 15U - Lighting System Group 15V - Work Lights Group 15WA - Stop Lights, Horn, Electrical Outlet (Europe Only) Group 15WB - Stop Lights, Horn, Electrical Outlet (USA Only) Group 15X - Beacon Light Group 15Y - Fan, Air Conditioning System Group 15Z - Windshield Wiper-/Washer System Group 15AA - Radio, Interior Lighting Group 15AB - Rotary Radiator Screen, Reverse Travel Alarm Group 15AC - Cigarette Lighter, Seat Compressor Group 15AD - Discharge Spout Rinsing System Group 15AE - Discharge Spout Flap Adjustment Group 15AF - Main Electronic System Group 15AG - Metal Detector Group 15AH - Electronic Control Unit Group 15AJ - ROW-TRAK System Group 15AK - POWR-SAVR Group 15AL - 676 Rotary Harvesting Unit (North America) Section 241 - ELECTRICAL SYSTEM (FROM SERIAL NO. 504992) Group 05 - Preliminary Checks Group 06 - General Information Group 07 - Test Equipment Group 10 - Electrical System Diagrams Group 15A - Batteries, Starting Motor, Alternator Group 15B - Safety Switches, Basic Relays Group 15C - Engine Shut-Off Device Group 15D - Instruments Group 15E - Electronic INFOTRAK Monitor Group 15H - Turning Discharge Spout Group 15I - Raising/Lowering Discharge Spout Group 15K - Central Lubrication System Group 15L - Reel Horizontal Adjustment Group 15M - Raising Reel Group 15N - Reel Speed Adjustment Group 15O - 676 Rotary Harvesting Unit (North America) Group 15P - Attaching Trailer Group 15Q - Raising/Lowering Harvesting Unit Group 15R - Pressure Valves, Trailer Dump Group 15S - Main Clutch, Reverser Group 15T - Four-Wheel Drive Group 15U - Lighting System Group 15V - Work Lights Group 15WA - Stop Lights, Horn, Electrical Outlet (Europe Only) Group 15WB - Stop Lights, Horn, Electrical Outlet (USA Only) Group 15X - Beacon Light Group 15Y - Fan, Air Conditioning System Group 15Z - Windshield Wiper/Washer System Group 15AA - Radio, Interior Lighting Group 15AB - Rotary Radiator Screen, Reverse Travel Alarm Group 15AC - Cigarette Lighter, Seat Compressor Group 15AD - Discharge Spout Rinsing System Group 15AE - Discharge Spout Flap Adjustment Group 15AF - Main Electronic System <- Go to Global Table of contents

tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 15AG - Metal Detector Group 15AH - Electronic Control Unit Group 15AJ - ROW-TRAK System Group 15AK - POWR-SAVR Group 15AL - 676 Rotary Harvesting Unit (North America) Group 15AM - Cutterhead Alarm Section 250 - POWER TRAIN Group 05 - Angled Drive Group 10 - Hydrostatic Drive Group 15 - Three-Speed Transmission Group 20 - Testing Hydrostatic System Section 260 - BRAKES, STEERING, REAR AXLE Group 05 - Brake Operating System Group 10 - Drum Brakes Group 15 - ROW-TRAK ROW-TRAK is a trademark of Deere & Company. System Group 20 - ROW-TRAK ROW-TRAK is a trademark of Deere & Company. Steering Function Group 25 - ROW-TRAK ROW-TRAK is a trademark of Deere & Company. Calibration Section 270 - HYDRAULIC SYSTEM Group 05 - General Information Group 10 - Electromagnetic Control Valve Group 15 - Testing Hydraulic System Group 20 - Header Float System Section 290 - OPERATOR′S CAB Group 05 - System Operational Checks Group 10 - System Diagnosis - Air Conditioning System, Operator′s Seat Group 20 - Theory of Operation

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tm4631-DIAGNOSIS AND TESTS MANUAL

<- Go to Global Table of contents

tm4631-DIAGNOSIS AND TESTS MANUAL

SAFETY

(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.

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.

"Right-hand" and "left-hand" refer to the machine as seen in forward travel.

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 05 page 1

tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Section 05 - SAFETY Table of contents Group 05 - Safety Information ............................................................................................................... 1 Live With Safety ................................................................................................................................... 1 Support Machine Properly .................................................................................................................... 1 Wear Protective Clothing ...................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 2 Work in Clean Area ............................................................................................................................... 2 Parking and Leaving the Forage Harvester ........................................................................................... 3 Remove Paint Before Welding or Heating ............................................................................................. 4 Handle Fluids Safely-Avoid Fires ........................................................................................................... 4 Prevent Acid Burns ............................................................................................................................... 6 Prevent Battery Explosions ................................................................................................................... 6 Avoid Heating Near Pressurized Fluid Lines .......................................................................................... 8 Illuminate Work Area Safely ................................................................................................................. 8 Replace Safety Signs ............................................................................................................................ 8 Use Proper Lifting Equipment ............................................................................................................... 9 Service Tires Safely ............................................................................................................................ 10 Practice Safe Maintenance ................................................................................................................. 11 Avoid High-Pressure Fluids ................................................................................................................. 11 Use Proper Tools ................................................................................................................................. 12 Service Machines Safely ..................................................................................................................... 12 Dispose of Waste Properly .................................................................................................................. 13

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tm4631-DIAGNOSIS AND TESTS MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Group 05 - Safety Information 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.

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 05 page 1

tm4631-DIAGNOSIS AND TESTS MANUAL

Section 05 - SAFETY

Group 05: Safety Information

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.

Prepare for Emergencies

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. <- Go to Section TOC

Section 05 page 2

tm4631-DIAGNOSIS AND TESTS MANUAL