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 Combine Repair
TM112019
Alternators and Starting Motors
CTM77
PowerTech Plus 4.5L and 6.8L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR
CTM320
PowerTech 4.5 L and 6.8 L Diesel Engines Level 11 Electronic Fuel System With Denso HPCR
CTM220
120 Series Hydraulic Cylinders
CTM120519
120 Series Hydraulic Cylinders
CTM114319
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
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 <- Go to Global Table of contents
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 <- Go to Global Table of contents
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 <- Go to Global Table of contents
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
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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 <- Go to Global Table of contents
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