John Deere W540, W550, W650, W660, T550, T560, T660, T670, C670 Combine Repair Technical Manual TM40

W540, W550, W650, W660, T550, T560, T660, T670 and C670 Including HillMaster Combines Repair (European Edition) REPAIR TECHNICAL MANUAL Combines models C670, T550, T560, T660, T670, W540, W550, W650, W660 TM401519 06JUL14 (ENGLISH)

For complete service information also see: Combines W540, W550, W650, W660, T550, T560,T660, T670, C670 Diagnostics

TM401619

JDLink Diagnosis and Tests Manual

tm106919

GreenStar 2 Diagnosis and Tests Manual TM1061 Alternators and Starting Motors

CTM77

CTM441 - Machine Connection Information

CTM441

PowerTech 9.0 L OEM Diesel Engines Base Engine Repair

CTM400

PowerTech 9.0 L Diesel Engines Level 14 CTM385 Electronic Fuel System With Denso HPCR PowerTech Plus 4.5L and 6.8L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR

CTM320

PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier CTM104 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine) JDLINK/ZXLINK Machine Monitoring System

CTM10006

John Deere Agriculture

TM401519-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Table of contents FOREWORD Section 10 - GENERAL Group 05 - Safety Group 10 - Specifications Group 15 - Fuel, Lubricants, Oils, Coolant and Capacities Section 20 - ENGINE Group 05 - Remove and Install Engine Group 10 - Lower Engine Repair Group 15 - Cooling System Section 30 - FUEL AND AIR INTAKE SYSTEMS Group 05 - Air Intake System Group 10 - Diesel Fuel System Section 40 - ELECTRICAL SYSTEM Group 05 - Harness and Connector Repair Group 10 - Wiring Harness Routings Group 15 - Fuses, Circuit Breakers and Relays Group 20 - Lights Group 25 - Operator′s Station Group 30 - Sensors and Switches Group 35 - Wiper Group 40 - Alternator Group 45 - Starter Motor Group 50 - GreenStar Components Section 50 - DRIVE TRAIN Group 05 - Transmission and Differential Group 10 - Final Drive Group 15 - Hydrostatic System Group 20 - Cam Lobe Motor Group 25 - HillMaster II Section 60 - POWER STEERING AND BRAKES Group 05 - Steering Group 10 - Brake Group 15 - Trailer Hitch Section 70 - HYDRAULIC SYSTEM REPAIR Group 05 - Hydraulic Reservoir Group 10 - Hydraulic Pumps Group 15 - Hydraulic Valves Group 20 - Hydraulic Cylinders Group 21 - HillMaster II Hydraulic Cylinders Group 25 - Motors Group 30 - Accumulators Section 80 - SEPARATOR SHELL Group 05 - Gull Wing Doors Group 10 - Hood - W Series, T Series Group 15 - Hood - C Series Section 90 - OPERATOR′S STATION REPAIR Group 05 - Air-Conditioning System (R134a) Group 10 - System Components Group 15 - Cab Section 110 - FEEDER HOUSE REPAIR Group 05 - Conveyor Group 10 - Upper Shaft and Slip Clutch <- Go to Global Table of contents

TM401519-REPAIR TECHNICAL MANUAL

TM401519-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Group 15 - Feeder House Drives and Reverser Gear Case Group 20 - HeaderTrak Tilt Cylinder and Frame Group 25 - HillMaster II Tilt Cylinder and Frame Section 120 - SEPARATOR - W SERIES Group 05 - Separator Repair Group 10 - Cylinder Drives Group 15 - Straw Walkers, Crankshafts and Walker Return Pan Group 20 - Straw Chopper and Chaff Spreader Group 25 - Shoe Supply Augers, Cleaning Fan and Chaffer and Sieve Frame Group 30 - Tailings Elevator and Augers Group 35 - Primary Countershaft Group 40 - Header Electromagnetic Clutch Assembly Section 121 - SEPARATOR - C SERIES Group 05 - Beaters Group 10 - Engine Gear Case to Module Drives Group 15 - Tine Separator Module Group 20 - Tine Separator Gear Cases Group 25 - Supply Augers (Shoe), Chaffer and Sieve Frame Group 30 - Straw Chopper Section 122 - SEPARATOR - T SERIES Group 01 - Common Separator Components Group 10 - Separator Components and Separator Drive Group 30 - Straw Walker Drive Group 60 - Remove and Install Beater Grate Group 65 - Remove and Install Beater Group 70 - Remove and Install Separator Rotor Group 75 - Remove and Install Separator Grate Group 80 - Remove and Install Overshot Beater Group 85 - Remove and Install Stripper Roll Section 130 - GRAIN TANK AND UNLOADING SYSTEM Group 05 - Grain Tank Cross Augers Group 10 - Unloading Auger System Drives Group 15 - Vertical Auger and Lower Gear Case Group 20 - Horizontal Auger and Gear Case Group 25 - Clean Grain Elevator and Loading Auger Gear Case Group 30 - Grain Tank and Extensions Section 140 - ENGINE GEAR CASE AND CONTROL VALVE, REPAIR Group 05 - Engine Gear Case and Valve Section 199 - SPECIAL TOOLS Group 05 - Essential Special Tools Group 10 - Recommended Special Tools

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TM401519-REPAIR TECHNICAL MANUAL

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TM401519-REPAIR TECHNICAL 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 10 page 1

TM401519-REPAIR TECHNICAL MANUAL

TM401519-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Section 10 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 1 Prepare for Emergencies ...................................................................................................................... 2 Handle Fluids Safely—Avoid Fires ......................................................................................................... 2 Prevent Acid Burns ............................................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 4 Park Machine Safely ............................................................................................................................. 5 Live With Safety ................................................................................................................................... 6 Support Machine Properly .................................................................................................................... 6 Wear Protective Clothing ...................................................................................................................... 7 Work in Clean Area ............................................................................................................................... 7 Service Machines Safely ....................................................................................................................... 8 Work In Ventilated Area ........................................................................................................................ 8 Illuminate Work Area Safely ................................................................................................................. 8 Replace Safety Signs ............................................................................................................................ 9 Use Proper Lifting Equipment ............................................................................................................... 9 Service Tires Safely ............................................................................................................................ 11 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 12 Remove Paint Before Welding or Heating ........................................................................................... 12 Use Proper Tools ................................................................................................................................. 13 Practice Safe Maintenance ................................................................................................................. 14 Protect Against Noise ......................................................................................................................... 14 Dispose of Waste Properly .................................................................................................................. 15 Avoid Harmful Asbestos Dust ............................................................................................................. 15 Group 10 - Specifications ..................................................................................................................... 17 Operating Speeds ............................................................................................................................... 17 Specifications - W540 and W550 Combines ....................................................................................... 18 Specifications - W650 and W660 Combines ....................................................................................... 19 Specifications - T550 and T560 Combines .......................................................................................... 20 Specifications - T660 and T670 Combines .......................................................................................... 21 Specifications - C670 Combine ........................................................................................................... 22 Dimension Reference Points (W Series) .............................................................................................. 23 Dimensions (W Series) ........................................................................................................................ 24 Dimension Reference Points (T Series) ............................................................................................... 25 Dimensions (T Series) ......................................................................................................................... 26 Dimension Reference Points (C Series) .............................................................................................. 27 Dimensions (C Series) ........................................................................................................................ 28 Metric Bolt and Screw Torque Values ................................................................................................. 29 Unified Inch Bolt and Screw Torque Values ........................................................................................ 30 Assemble and Install Flat Face Seal Fittings - All Pressure Applications ............................................. 30 Torque Chart for Metric Flat Face Seal Fittings - Standard Pressure Applications .............................. 32 Torque Chart for Metric Flat Face Seal Fittings - High Pressure Applications ..................................... 33 Torque Chart for SAE Flat Face Seal Fittings - Standard Pressure Applications .................................. 34 Torque Chart for SAE Flat Face Seal Fittings - High Pressure Applications ......................................... 35 Assemble and Install Four-Bolt Flange Fittings - All Pressure Applications ......................................... 35 Torque Values for SAE Four-Bolt Flange - Standard Pressure Applications ......................................... 37 Torque Values for SAE Four-Bolt Flange - High Pressure Applications ................................................ 38 Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled <- Go to Global Table of contents

TM401519-REPAIR TECHNICAL MANUAL

TM401519-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Systems ....................................................................................................................................... 38 Group 15 - Fuel, Lubricants, Oils, Coolant and Capacities .............................................................. 39 Diesel Fuel .......................................................................................................................................... 39 Storing Fuel ........................................................................................................................................ 39 Heavy Duty Diesel Engine Coolant ..................................................................................................... 40 Supplemental Coolant Additives ......................................................................................................... 40 Liquid Coolant Conditioner ................................................................................................................. 41 Diesel Engine Oil ................................................................................................................................ 42 Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils ......................... 43 Transmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger Elevator and Dual-Range Cylinder Drive Gear Cases ....................................................................................... 44 Grease ................................................................................................................................................ 45 Lubricant Storage ............................................................................................................................... 45 Alternative and Synthetic Lubricants .................................................................................................. 46 Capacities ........................................................................................................................................... 47

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TM401519-REPAIR TECHNICAL MANUAL

Section 10 - 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.

Understand Signal Words

Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this manual.

Prevent Battery Explosions

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Section 10 page 1

TM401519-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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).

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.

Handle Fluids Safely—Avoid Fires

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Section 10 page 2

TM401519-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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Section 10 page 3

TM401519-REPAIR TECHNICAL MANUAL