John Deere Combines S540, S550, S660, S670, S680, S690 Repair Service Technical Manual (TM803819)
Complete service repair manual for John Deere Combines S540, S550, S660, S670, S680, S690, with all the technical information to maintain, repair, and rebuild like professional mechanics.
John Deere Combines S540, S550, S660, S670, S680, S690 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM803819 - John Deere Combines S540, S550, S660, S670, S680, S690 Technical Manual (Repair).PDF
TM803819 - John Deere Combines S540, S550, S660, S670, S680, S690 Technical Manual (Repair).epub
Total Pages: 2,548 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
General
Safety
Specifications
Tune-Up and Adjustment
Fuels and Lubricants
Engine
Remove and Install Engine
Cooling System
Fuel and Air
Air Intake System
Diesel Fuel System
Electrical System
Batteries
Harness and Connector Repair
Wire Harness Routing
Controllers and Power Distribution
Lighting
Operators Station
Sensors and Switches
Wiper
Alternator
Starting Motor
GreenStar Components
Power Train
Transmission and Differential-Three Speed Transmission
Transmission and Differential-Two-Range Automatic Transmission
Hydrostatic Drive Pump-Two-Range Automatic Transmission
Hydrostatic Drive Motor-Two-Range Automatic Transmission
Single Reduction Final Drive
Cam Lobe Motor
Tires and Wheels
Steering and Brakes
Steering
Brakes
Brakes-Two-Range Automatic Transmission
Hydraulic System
Hydraulic Reservoir
Hydraulic Motors and Pumps
Hydraulic Valves
Hydraulic Cylinders
Accumulators
Separator Shell
Gull Wing Doors
Fiberglass Repair
Operator Station
Air Conditioning System (R134a)
System Components
Cab
Feeder House
Conveyor
Top Shaft and Slip Clutch
Feeder House Drives and Reverser Gear Case
Fore Aft and Lateral Tilt Frame
Five Speed Feeder House Drive Gear Case
Separator
Separator Repair
Separator Drives
Residue Disposal
Conveyor Augers, Cleaning Fan and Chaffer and Sieve Frame
Tailings Elevator and Augers
Primary Countershaft Gear Case
Header Electromagnetic Clutch
Grain Tank and Unloading System
Grain Tank Cross Augers
Unloading Auger System Drives
Vertical Unloading Auger and Lower Gear Case
Horizontal Unloading Auger and Gear Case
Clean Grain Elevator
Engine Gear Case and Control Valve
Engine Gear Case and Valve
Dealer Fabricated Tools
Dealer Fabricated Tools
tm803819 - S540, S550, S660, S670 and S680 Combine Repair
Table of Contents
Foreword
Section 10: General
Group 05: Safety
Recognize Safety Information
Understand Signal Words
Remove Paint Before Welding or Heating
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Handling Batteries Safely
Prepare for Emergencies
Prevent Acid Burns
Avoid High-Pressure Fluids
Service Accumulator Systems Safely
Wait Before Opening High-Pressure Fuel System
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Service Tires Safely
Avoid Harmful Asbestos Dust
Work in Clean Area
Practice Safe Maintenance
Use Proper Tools
Construct Dealer-Made Tools Safely
Avoid Heating Near Pressurized Fluid Lines
Dispose of Waste Properly
Use Adequate Service Facilities
Live With Safety
Servicing Electronic Control Units
Welding Near Electronic Control Units
Precautions for Welding
Keep Electronic Control Unit Connectors Clean
Clean Exhaust Filter Safely
Group 10: Specifications
Engine
Electrical System
Transmission and Brakes
Feeding
Separator
Discharge
Elevators and Cleaning Fan
Unloading
Turning Radius
Weight
Capacities
Dimensions
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Sealants and Adhesives Cross-Reference Chart
Face Seal Fittings Assembly and Installation—All Pressure Applications
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications
Group 15: Tune-Up and Adjustment
Tune-Up and Adjustment
Care and Maintenance of Belts
Defective Belts
Prevent Hydraulic System Contamination
Check Oil Lines and Fittings
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems
Group 20: Fuels and Lubricants
Handle Fuel Safely—Avoid Fires
Fuel Tank—Filling
Handling and Storing Diesel Fuel
Diesel Fuel
BioDiesel Fuel
Lubricity of Diesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Heavy Duty Diesel Engine Coolant
Drain Intervals for Diesel Engine Coolant
John Deere COOL-GARD™ II Coolant Extender
Supplemental Coolant Additives
Operating in Warm Temperature Climates
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender
Testing Diesel Engine Coolant
Diesel Engine Break-In Oil (Tier 2/Stage II)
Diesel Engine Oil (Tier 2/Stage II)
Engine Oil and Filter Service Intervals (Tier 2/Stage II)
Oilscan™ and CoolScan™
Hydrostatic Drive System, Main Hydraulic System and Main Engine Gearcase Oils
Transmission, Final Drives, Loading Auger, Primary Countershaft and Two-Speed Separator Drive Gearcases
Feeder House Reverser Gearcase
Grease
Brake Fluid (If Equipped)
Oil Filters
Fuel Filters
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Section 20: Engine
Group 05: Remove and Install Engine
Specifications
John Deere Engine Repair—Use CTM
Remove Engine—6.8 L
Install Engine—6.8 L
Remove Engine—9.0 L
Install Engine—9.0 L
Remove Engine—13.5 L
Install Engine—13.5 L
Remove and Install Fan Drive Bearing and Support—13.5 L Engine
Remove and Install Flywheel Pilot Bearing
Group 10: Cooling System
Specifications
John Deere Engine Repair—Use CTM
Rotary Screen Drive Exploded View
Rotary Screen Idler Arm and Sheaves Exploded View
Remove and Install Air Scoop Panel
Remove and Install Service Door Panel
Rotary Screen Exploded View—6.8L and 9.0L Engines
Rotary Screen Exploded View—13.5L Engine
Remove and Install Rotary Screen Door
Remove and Install Rotary Screen
Adjusting Rotary Screen Knife Comb
Remove Cooling Package—13.5L Engine
Install Cooling Package—13.5L Engine
Remove Radiator—6.8L and 9.0L Engines
Install Radiator—6.8L and 9.0L Engines
Remove Radiator—13.5L Engine
Install Radiator—13.5L Engine
Remove and Install Oil Cooler—6.8L and 9.0L Engines
Remove and Install Oil Cooler—13.5L Engine
Test Cooling System
Remove and Install Surge Tank—6.8L Engine
Remove and Install Surge Tank—9.0L and 13.5L Engines
Test Surge Tank Cap
Section 30: Fuel and Air
Group 05: Air Intake System
Specifications
John Deere Engine Repair—Use CTM
Remove and Install Charge Air Cooler—6.8L and 9.0L Engines
Remove and Install Charge Air Cooler—13.5L Engine
Cleaning Charge Air Cooler
Group 10: Diesel Fuel System
Remove and Install Fuel Tank Shutoff Valve—Type A
Remove and Install Fuel Tank Shutoff Valve—Type B
Remove and Install Fuel Prefilter—Type A
Remove and Install Fuel Prefilter—Type B
Remove and Install Fuel Prefilter—Type C
Remove and Install Fuel Prefilter—Type D
Remove and Install Fuel Tank—S540 and S550
Remove and Install Fuel Tank—S660, S670, S680 and S690
Replace Fuel Tank Wear Strips
Remove and Install Fuel Cooler—6.8L and 9.0L Engines
Remove and Install Fuel Cooler—13.5L Engine
Remove and Install Fuel Tank Strainer and Breather
Section 40: Electrical System
Group 05: Batteries
Specifications
Prevent Battery Explosions
Handling Batteries Safely
Prevent Damage to Electrical Systems
Checking Electrolyte Specific Gravity
Remove and Install Batteries—Style A
Remove and Install Batteries—Style B
Battery Vent Hose Replacement—Style B
Connecting Booster Batteries
Charging Batteries
Connecting Battery Cables
Group 10: Harness and Connector Repair
Use Electrical Insulating Compound
Using High-Pressure Washers
Electrical System Visual Inspection
Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer Controlled Systems
Electrical Connector / Wiring Harness Handling and Repair
Repair Procedure R-A
Repair Procedure R-B
Repair Procedure R-C
Repair Procedure R-D
Repair Procedure R-E
Repair Procedure R-F
Repair Procedure R-G
Repair Procedure R-I
Repair Procedure R-J
Repair Procedure R-K
Repair Procedure R-M
Repair Procedure R-N
Repair Procedure R-AE
Repair Procedure R-AF
Repair Procedure R-AG
Repair Procedure R-AH
Repair Procedure R-AI
Repair Procedure R-AJ
Repair Procedure R-AK
Repair Procedure R-AL
Repair Procedure R-AR
Repair Procedure R-AS
Repair Procedure R-AT
Group 15: Wire Harness Routing
Replace Harness
Cab Main Wiring Harness
Cab Roof Wiring Harness
LC1 Wiring Harness—Open Center Hydraulics
LC1 Wiring Harness—Closed Center Hydraulics
LC2 Wiring Harness—Open Center Hydraulics
LC2 Wiring Harness—Closed Center Hydraulics
Right-Hand Main Wiring Harness—Open Center Hydraulics
Right-Hand Main Wiring Harness—Closed Center Hydraulics
Engine Deck Wiring Harness
Group 20: Controllers and Power Distribution
Fuse Center Cover
Fuse Center—S540 and S550
Fuse Center—S660 and S670
Fuse Center—S680 and S690
Remove and Install HVAC Power Module
Remove and Install Right and Left Power Modules and Control Units
Remove and Install Cab Power Module
Programming Control Units
Group 25: Lighting
Specifications
Safety Rules When Replacing Halogen Bulbs
Cab Halogen Round Headlight Bulb Replacement and Adjustment
Cab Halogen Oval Light Bulb Replacement and Adjustment
Auxiliary Field, Access Door, Unload Auger and Work Light Bulb Replacement
Side Finder Light Bulb Replacement
Rotary Beacon Bulb Replacement
Rear Hazard, Marker, Brake, and Turn Signal Light Bulb Replacement
Cleaning Shoe Light Bulb Replacement
Dome Light Bulb Replacement
Header Flood Light Bulb Replacement (If Equipped)
Remove and Install Header Flood Light Housing (If Equipped)
Remove and Install Grain Tank Light Assembly
Group 30: Operators Station
Specifications
Instruments and Controls Identification
Remove and Install Overhead Console
Remove and Install Radio
Remove and Install Radio Speaker
Remove and Install Radio Antenna Base Assembly
Remove and Install Mobile Radio Antenna
Replace Corner Post Display
Remove and Install Auxiliary Power Outlet Strip
Armrest Console Connector Locations
Remove and Install Side Console
Remove and Install Multi-Function Lever
Remove and Install Armrest Display Unit
Remove and Install Header and Separator Engage Switches
Remove and Install Dial-A-Speed and Active Header Control Switches
Remove and Install Armrest Console Switch Panel
Remove and Install Multi-Function Lever Position Switches
Remove and Install Ignition Switch
Remove and Install Steering Column Lever
Remove and Install Remote Mirrors
Remove and Install Remote Mirror Adjustment Switch
Remove and Install Heated Mirror Switch
Remove and Install Map Light Assembly
Group 35: Sensors and Switches
Specifications
Shaft Speed Sensor Locations
Remove and Install Ground Speed Sensor
Remove and Install Low Shaft Speed Sensor
Remove and Install STS Rotor Speed Sensor
Remove and Install Full Grain Tank Sensor
Remove and Install Straw Spreader Speed Sensor
Remove and Install Tailings Sensor
Remove and Install (Shoe/Separator) VisionTrak™ Sensors
Remove and Install Header Height, Lateral Tilt and Rear Tag Axle Sensors
Remove and Install Multi-Function Lever Feed Rate Sensor
Remove and Install Hydraulic Reservoir Temperature Sensor
Remove and Install Coolant Temperature Sensor
Remove and Install Surge Tank Level Switches
Remove and Install Fuel Level Sensor—Type A
Remove and Install Fuel Level Sensor—Type B
Remove and Install Park Brake Switch
Remove and Install Steering Input Device Sensor
Remove and Install Accumulator Charge Pressure Sensor
Remove and Install Engine Gear Case Temperature and Pressure Switches
Remove and Install Hydrostatic Charge Pressure Switch—Open Center Systems
Remove and Install Hydrostatic Charge Pressure and Direction Pressure Switches—Closed Center Systems
Remove and Install Hydraulic Reservoir Filter Sensor—Closed Center Systems
Remove and Install Evaporator Temperature Sensor
Remove and Install Air Temperature Sensors
Remove and Install Variable Speed Fan Driven Sensor
Remove and Install Switches in the Ground Level Switch Bank
Remove and Install Electromagnetic Clutch Brush Module Sensor
Remove and Install Header Height Arm Position Sensor
Remove and Install Horizontal Unloading Auger Arm Position Sensor
Remove and Install Lateral Tilt Position Sensor
Disassemble and Assemble Arm Position Sensors
Remove and Install Wheel Angle Sensor
Remove and Install Folding Horizontal Auger Sensor
Remove and Install Chopper Position Sensor — Style A
Remove and Install Chopper Position Sensor — Style B
Group 40: Wiper
Specifications
Remove and Install Windshield Wiper Arms
Remove and Install Windshield Wiper Motor
Remove and Install Windshield Washer
Adjust Windshield Wiper Arms
Group 45: Alternator
Specifications
John Deere Engine Accessories—Alternator Repair
Remove And Install Alternator And Alternator Belt
Remove and Install Alternator Pulley
Group 50: Starting Motor
Specifications
John Deere Starting Motor Repair
Remove and Install Starting Motor
Group 55: GreenStar Components
Specifications
Remove and Install Mass Flow Sensor
Moisture Sensor Assembly Exploded View
Remove and Install Moisture Sensor Assembly
Remove and Install Grain Moisture Sensor
Remove and Install Proximity Switch
Remove and Install Auger Motor
Position Receiver and Base Exploded View
Remove and Install Position Receiver
Disassemble and Assemble Position Receiver
Section 50: Power Train
Group 05: Transmission and Differential—Three Speed Transmission
Specifications
Remove Three Speed Transmission
Remove and Repair Shifter Forks and Shifter Cam
Install Shifter Forks and Shifter Cam
Remove and Install Suction Screen
Transmission Components
Disassemble and Repair Transmission
Assemble Three Speed Transmission
Install Three Speed Transmission
Remove and Install Gearshift Lever and Linkage
Adjust Gearshift Linkage
Remove and Install Transmission Lube Pump
Group 10: Transmission and Differential—Two-Range Automatic Transmission
Specifications
Drain Oil
Remove Two-Range Automatic Transmission
Transmission Components—Overview
Remove and Install Countershaft and Planetary Drive Cover
Check Countershaft and Planetary Shaft End Play
Remove Brake Assemblies
Disassemble Brake Assemblies
Assemble Brake Assemblies
Install Brake Assemblies
Remove and Install Park Brake Housing
Disassemble and Assemble Park Brake
Remove and Install Differential Module
Disassemble Differential Module (With Differential Lock)
Assemble Differential Module (With Differential Lock)
Remove Gear-Shift Planetary Drive with Clutch
Disassemble and Assemble Gear-Shift Planetary Drive With Clutch
Install Gear-Shift Planetary Drive With Clutch
Remove and Install Countershaft
Repair Countershaft
Remove and Install Filter Screen
Remove and Install Proportionator Motor
Replace Proportionator Motor Bushing
Assemble Two-Range Automatic Transmission
Install Two-Range Automatic Transmission
Group 15: Hydrostatic Drive Pump—Two-Range Automatic Transmission
Specifications
Remove and Install Hydrostatic Pump—Two-Range Automatic Transmission
Replace Drive Shaft Seal
Replace Boost Pump Seal
Replace Control Piston Cover Seals
Replace Boost Pressure Valve Seals
Replace Pressure Cut Off Valve Seals
Remove and Install Control Unit
Disassemble Pump
Disassemble Cylinder Assembly
Disassemble Control Piston
Inspection Notes—Two-Range Automatic Transmission—Hydrostatic Pump
Assemble Pump
Install Rotary Group
Adjust Zero Position
Group 20: Hydrostatic Drive Motor—Two-Range Automatic Transmission
Specifications
General View
Remove and Install Hydrostatic Drive Motor
Replace Cover Plate Seal
Replace Port Plate Control Seals
Group 25: Single Reduction Final Drive
Specifications
Remove and Install Final Drive
Disassemble and Assemble Final Drive
Adjust Spindle Bearing (Preferred Method)
Adjust Spindle Bearing (Alternate Method)
Remove and Install Left- and Right-Hand Rocker Assembly
Group 30: Cam Lobe Motor
Specifications
Flushing Cam Lobe Motors
Remove and Install Cam Lobe Motor
Remove and Install Cam Lobe Motor Control Valve
Disassemble and Assemble Cam Lobe Motor Control Valve
Remove and Install Steering Yoke
Disassemble and Assemble Pivot Pins, Bushings, and Seals
Remove and Install Solenoid Valve and Valve Block
Remove and Install Displacement Control Valve
Remove and Install Cam and Piston Carrier
Remove and Install Stack Valve Seals
Remove and Install Axle Bearings and Seals
Group 35: Tires and Wheels
Specifications
Service Tires Safely
Jacking Locations
Remove and Install Tire
Drive Wheel Starter Stud
Drive Wheel Bolt Torque—Single Wheel Configuration
Drive Wheel Bolt Torque—Dual Wheel Configuration
Install Dual Wheels and Truss Rod
Rear Wheel Bolt Torque
Using Liquid Weight
Install Axle Extension Tubes
Section 60: Steering and Brakes
Group 05: Steering
Specifications
Remove Steering Valve
Steering Valve-Closed Center Hydraulics
Disassemble Electro-Hydraulic Open Center Steering Valve
Assemble Electro-Hydraulic Open Center Steering Valve
Install Steering Valve
Remove and Install Electro-Hydraulic Closed Center Steering Valve
Disassemble and Assemble Electro-Hydraulic Closed Center Steering Valve
Steering Column Exploded Views
Remove and Install Steering Wheel
Remove and Install Steering Column Covers
Remove and Install Steering Column
Remove and Install Steering Column Harness
Remove and Install Steering Column Tilt Struts
Remove and Install Steering Column Pivots
Remove and Install Steering Column Link Shaft
Remove and Install Tilt Adjust Pedal and Linkage
Remove and Install Steering Cylinder
Bleed Steering Cylinder
Steering Cylinder Exploded View
Toe-In Adjustment
Remove and Install Steering Tie Rod Joint
Remove and Install Tie Rod End
Remove and Install Rear Spindle Assembly—Non-Powered
Disassemble and Assemble Rear Spindle Assembly—Non-Powered
Remove and Install Rear Axle Pivot Bushings
Rear Axle Adjustment
Remove and Install Hitch
Remove and Install Hitch Extension
Group 10: Brakes
Specifications
Deglazing Brake Linings
Remove and Install Brake Drum
Remove Brake Shoe
Repair Brakes
Assemble Brakes
Remove and Install Master Cylinder
Adjusting Master Cylinder
Brake Fluid Reservoir
Bleeding Brake System
Remove and Install Slave Cylinders
Disassemble and Assemble Slave Cylinder
Disassemble and Assemble Brake Pedals
Disassemble and Assemble Parking Brake Pedal
Adjust Park Brake Pedal
Group 15: Brakes—Two-Range Automatic Transmission
Park Brake Release—Two Range Automatic Transmission
Bleed Service Brakes
Disassemble and Assemble Brake Pedals—Two Range Automatic Transmission
Service Brake Repair
Section 70: Hydraulic System
Group 05: Hydraulic Reservoir
Specifications
Remove and Install Hydraulic Reservoir—S540 and S550
Remove and Install Hydraulic Reservoir—S660 and S670
Remove and Install Hydraulic Reservoir—S680 and S690
Flushing Hydraulic System
Flushing Reel/Belt Pickup Drive System
Start-Up Procedure After Hydrostatic System Repair—After Reservoir Remove and Install
Group 10: Hydraulic Motors and Pumps
Specifications
Remove Main Hydraulic Pump
Marking Hydraulic Pump
Disassemble Hydraulic Pump
Replace Seal
Triple Main Hydraulic Pump Exploded View
Quad Main Hydraulic Pump Exploded View
Assemble Triple Main Hydraulic Pump
Assemble Quad Main Hydraulic Pump
Install Main Hydraulic Pump
Proportionator Motor Exploded View
Disassemble and Assemble Proportionator Motor
Reel/Belt Pickup and Straw Spreader Pump Exploded View
Remove and Install Reel/Belt Pickup Pump Drive
Disassemble and Assemble Reel/Belt Pickup Pump Drive
Remove Spreader Pump
Install Spreader Pump
Remove and Install Main Engine Gear Case Lubrication Pump
Disassemble and Assemble Gear Pump
Remove and Install Piston Pump
Disassemble and Assemble Piston Pump
Remove and Install Hydraulic Transfer Gear Case
Disassemble and Assemble Hydraulic Transfer Gear Case
Group 15: Hydraulic Valves
Specifications
Disassemble and Assemble Hydraulic Valve Stack (HIC)
Remove and Install Hydraulic Valve Stack (HIC)
Disassemble and Assemble Hydraulic Valve Stack (HIC)
Remove and Install Transmission Control Valve
Two-Range Automatic Transmission Control Valve Repair
Remove and Install Hydraulic Service Brake Valve
Disassemble and Assemble Hydraulic Service Brake Valve
Adjust Hydraulic Service Brake Valve
Feeder House Multi-Coupler Valve Identification
Disassemble, Inspect and Assemble Feeder House Multi-Coupler
Remove and Install Variable Speed Fan Drive Valve Block
Disassemble and Assemble Variable Speed Fan Drive Valve Block
Remove and Install Spreader Control Valve Block—Type A
Disassemble and Assemble Spreader Control Valve Block—Type A
Remove and Install Spreader Control Valve Block—Type B
Disassemble and Assemble Spreader Control Valve Block—Type B
Remove and Install Brake Priority Valve Block—S670
Remove and Install Header Height Control Valve Block—S540, S550, S660 and S670
Disassemble and Assemble Header Height Control Valve Block—S540, S550, S660 and S670
Remove and Install Header Height Valve Block—S680 and S690
Disassemble and Assemble Header Height Valve Block—S680 and S690
Remove and Install Reel Position/Platform Tilt Valve Block
Disassemble and Assemble Reel Position/Platform Tilt Valve Block
Disassemble and Assemble Feeder House Hydraulic Fore/Aft Tilt Valve
Remove and Install Left Front Valve Block
Disassemble and Assemble Left Front Valve Block
Remove and Install Primary Control Valve Block
Disassemble and Assemble Primary Control Valve Block
Group 20: Hydraulic Cylinders
Specifications
John Deere 100 Series Hydraulic Cylinder Repair—Use CTM
Identification of CTM Language
Remove and Install Header Lift Cylinder
Disassemble and Assemble Header Lift Cylinder—Style A
Disassemble and Assemble Header Lift Cylinder—Style B
Lateral Tilt Cylinder Hoses and Fittings Exploded View
Lateral Tilt and Hydraulic Fore/Aft Tilt Cylinder-Exploded View
Remove and Install Feeder House Hydraulic Fore/Aft Tilt Cylinder
Remove and Install Lateral Tilt Cylinder—Hydraulic Fore/Aft Tilt
Remove and Install Lateral Tilt Cylinder—Single Cylinder
Remove and Install Unloading Auger Swing Cylinder
Unloading Auger Swing Cylinder Exploded View
Adjust Unloading Auger Swing Cylinder
Remove and Install Unloading Auger Drive Cylinder
Disassemble and Assemble Steering Cylinder
Group 25: Accumulators
Accumulator (General Information)
Checking Accumulator Pressure
Accumulator Precharge Pressures
Section 80: Separator Shell
Group 05: Gull Wing Doors
Remove and Install Gull Wing Doors
Remove and Install Rear Wall Panel
Composite Panel Repair
Align Gull Wing Doors
Remove and Install Engine Platform Ladder
Group 10: Fiberglass Repair
General Information and Materials
Repair Surface Scratches and Gouges
Preparing Backing Patch
Using Backing Patch
Repair Small Cracks
Repair Small Fractures
Repair Large Fractures
Finishing Surface
Section 90: Operator Station
Group 05: Air Conditioning System (R134a)
Specifications
Service Parts Kits
Hose and Tubing O-Ring Connection Torques
Discharge and Recovery of Air Conditioning Refrigerant
Test Volumetric Efficiency
Leak Testing Air Conditioning System With Dye
Test Shaft Seal Leakage
Check Clutch Hub Clearance
Inspect Compressor Manifold
System Information
Flush Air Conditioning System
Purge Air Conditioning System
Evacuate Air Conditioning System
Compressor Oil Information
Determine Correct Oil Charge
Check Refrigerant Oil Charge
Charge Air Conditioning System
Group 10: System Components
Specifications
Heating, Ventilating, and Air Conditioning System—HVAC (General Information)
Remove and Install Receiver/Dryer
Remove and Install Pressurizer Blower Motor
Remove and Install Recirculator Fan Motor Driver
Remove and Install Recirculator Fan Motor
Remove and Install Actuator Valves
Remove and Install Climate Control Unit
Remove and Install Heater Core
Remove and Install Compressor
Disassemble, Inspect, and Assemble Compressor
Disassemble and Assemble Compressor Clutch
Remove and Install Compressor Relief Valve
Remove Condenser—6.8L and 9.0L Engines
Install Condenser—6.8L and 9.0L Engines
Remove Condenser—13.5L Engine
Install Condenser—13.5L Engine
Repair Condenser
Remove and Install Evaporator
Replace Expansion Valve
Replace Air Conditioning High/Low Pressure Switch
Group 15: Cab
Specifications
Remove Cab
Install Cab
Remove and Install Cab Windshield
Remove and Install Emergency Exit Glass
Remove and Install Rear Window
Remove and Install Lower Cab Fascia
Remove and Install Front Portion of Cab Roof
Remove and Install Rear Portion of Cab Roof
Remove and Install Cab Inner Roof
Remove and Install Cab Headliner
Remove and Install Operator Seat
Remove and Install Armrest Control Pivot
Remove and Install Operator Presence Switch
Remove and Install Seat Cushions
Remove and Install Lap Belt
Remove and Install Left-Hand Armrest
Operator Seat Exploded View
Remove and Install Operator Air Seat Suspension
Seat Suspension Component Overview
Remove and Install Seat Suspension Bellows
Remove and Install Vertical Shock Absorber Control Cable Handle
Remove and Install Vertical Shock Absorber Control Cable
Remove and Install Vertical Shock Absorber
Remove and Install Horizontal Shock Absorber
Remove and Install Fore-Aft Isolator Assembly
Remove and Install Fore-Aft Isolator Handle
Remove and Install Fore-Aft Isolator Locking Mechanism
Remove and Install Seat Suspension Compressor
Remove and Install Seat Level Indicator
Remove and Install Seat Suspension Air Spring
Remove and Install Seat Air Reservoir
Remove and Install Seat Height Control
Remove and Install Upper Seat Suspension Frame
Remove and Install Lower Seat Suspension Frame
Remove and Install Refrigerator
Remove and Install Refrigerator Doors
Remove and Install Refrigerator Control Unit
Remove and Install Refrigerator Thermostat
Remove and Install Cab Door
Disassemble and Assemble Cab Door
Cab Door Latch Striker
Section 110: Feeder House
Group 05: Conveyor
Specifications
Remove and Install Feeder House—S540
Remove and Install Feeder House—S550, S660 and S670
Remove and Install Feeder House—S680 and S690
Adjust Feeder House Conveyor Chain—S540 and S550
Adjust Feeder House Conveyor Chain—S660, S670, S680 and S690
Remove and Install Conveyor Chain
Measure Conveyor Chain Wear
Removing Conveyor Chain Link
Replace Conveyor Chain Slats
Replace Conveyor Chain Wear Strips
Adjust Drum Height (Manual Tilt)
Remove and Install Conveyor Drum—S540 and S550
Remove and Install Conveyor Drum—S660, S670, S680 and S690
Remove and Install Sub-Floor Assembly
Remove and Install Mid-Floor Assembly—S540 and S550
Remove and Install Mid-Floor Assembly—S660, S670, S680 and S690
Remove and Install Feed Plate
Adjust Feed Plate Assembly
Feed Plate Support Exploded View
Group 10: Top Shaft and Slip Clutch
Specifications
Remove Top Shaft Slip Clutch
Disassemble and Assemble Top Shaft Slip Clutch
Install Top Shaft Slip Clutch
Remove and Install Top Shaft Supports
Disassemble and Assemble Top Shaft
Disassemble and Assemble Fixed Speed Countershaft
Group 15: Feeder House Drives and Reverser Gear Case
Specifications
Remove and Install Variable Drive Countershaft
Disassemble and Assemble Upper Variable Drive Countershaft
Remove, Repair and Install Variable Drive Sheaves and Cams (Heavy Duty)
Remove, Repair, and Install Variable Drive Sheaves and Cams (High Torque)
Remove and Install Multi-Speed Feeder House Countershaft
Remove and Install Fixed Drive Sheave
Remove and Install Reverser Gear Case
Remove and Install Oil Cooler
Feeder House Reverser Gear Case Exploded View
Disassemble and Assemble Feeder House Reverser Gear Case
Disassemble and Assemble Reverser Gear Case Oil Pump
Remove and Install Reverser Shift Piston
Remove and Install Lower Shaft
Disassemble and Assemble Fixed Speed Drive Tightener
Disassemble and Assemble 5 Speed Drive Tightener
Disassemble and Assemble Conveyor Drive Chain, Tightener, and Guides
Remove and Install Feeder House Fixed Speed Drive Belt
Remove and Install Feeder House Multi-Speed Drive Belt
Feeder House Variable Speed Drive Belt—Replacing
Feeder House Variable Speed Drive Belt—Adjusting
Group 20: Fore Aft and Lateral Tilt Frame
Specifications
Remove and Install Lateral Tilt Cylinder
Tilt Beam and Closure Plates Exploded View
Remove and Install Tilt Frame (Manual Tilt)
Remove and Install Tilt Frame (Hydraulic Tilt)
Remove and Install Tilt Beam with Latching Mechanism
Adjust Latching Mechanism
Lateral Tilt Beam with Latching Mechanism—Exploded View
Remove Fore-Aft Tilt Frame (Manual Tilt)
Install Fore-Aft Tilt Frame (Manual Tilt)
Remove Fore-Aft Tilt Frame (Hydraulic Tilt)
Install Fore-Aft Tilt Frame (Hydraulic Tilt)
Group 25: Five Speed Feeder House Drive Gear Case
Specifications
General Repair Procedures—Five Speed Gear Case
Remove and Install Five Speed Feeder House Drive Gear Case
Cross-Sectional View—Five Speed Feeder House Drive Gear Case
Cross-Sectional View—Gear Case Output Shaft
Disassemble Five Speed Feeder House Drive Gear Case
Disassemble and Assemble Gear/Clutch Assemblies
Assemble Five Speed Feeder House Drive Gear Case
Section 120: Separator
Group 05: Separator Repair
Specifications
Remove and Install Feed Accelerator and Shaft
Remove and Install Feed Accelerator Wear Strips
Remove and Install Separator Top Covers
Remove and Install Separator Rails
Remove and Install Front Rotor Bearing
Remove and Install Stone Trap Door
Remove and Install Rotor
Remove and Install Rotor Torque Sensing—Driven
Disassemble and Assemble Rotor Torque Sensing—Driven
Remove and Install Rotor Drive Gear Case
Disassemble and Assemble Rotor Drive Gear Case
Remove and Install Discharge Beater Grate Section
Remove and Install Discharge Beater Grate Frame
Remove and Install Discharge Beater Top Covers
Remove and Install Discharge Beater
Remove and Install Discharge Beater Drive Hub
Remove and Install Discharge Beater Housing
Remove and Install Separator Grates
Concave Inspection
Remove and Install Concave Sections
Adjust Concave Level
Remove and Install Concave Adjusting Motor
Remove and Install Concave Adjusting Tube and Sector Gear
Remove and Install Front Bulkhead
Remove and Install Center Bulkhead
Repair Separator Rotor Shell
Remove and Replace RIVNUT Threaded Inserts
Remove and Install Rotor Feed Flights
Static Balance Rotor
Aligning Rotor Drive Bulkhead
Remove and Install Threshing Elements and Tines—TriStream Rotor
Threshing Element and Separator Tine Location (TriStream Rotor Tough Grain Configuration)
Threshing Element and Separator Tine Location (TriStream Rotor Dense Pack Configuration)
Remove and Install Threshing Elements and Tines—Variable Stream Rotor
Threshing Element and Separator Tine Location (Variable Stream Rotor Standard Configuration)
Threshing Element and Separator Tine Location (Variable Stream Rotor Dense Pack Configuration)
Group 10: Separator Drives
Specifications
Remove and Install Right-Hand Front Jackshaft
Remove and Install Right-Hand Rear Jackshaft
Remove and Install Primary Countershaft Bearing
Remove and Install Primary Countershaft—Style A
Remove and Install Primary Countershaft—Style B
Remove and Install Primary Drive Shafts—Style A
Remove and Install Primary Drive Shafts—Style B
Replace Drive Shaft Carrier Bearing—Style A
Group 15: Residue Disposal
Specifications
Straw Chopper Vane Settings—Powered
Straw Chopper Tailboard—Powered
Remove and Install Tailboard
Straw Chopper Housing
Remove and Install Straw Chopper (S540 and S550)
Remove and Install Straw Chopper (S660, S670, S680 and S690)
Remove and Install Chopper Raise/Lower Actuator
Chopper Blades—Replacing and Configuration
Replace Stationary Knife Blades
Remove and Install Easy Adjust Knife Bank
Remove and Install Crop Diverter
Replace Left-Hand Chopper Rotor Bearing
Replace Right-Hand Chopper Rotor Bearing
Dual Speed Chopper Sheave Remove and Install (S540 and S550)
Dual Speed Chopper Sheave Remove/Install (S660, S670, S680 and S690)— Identification of Type
Dual Speed Chopper Sheave Remove/Install—Type A
Dual Speed Chopper Sheave Remove/Install—Type B
Repair Dual Speed Chopper Sheave Assembly
Chopper Drive Jackshaft Remove/Install— Identification of Type
Chopper Drive Jackshaft Remove/Install—Type A
Chopper Drive Jackshaft Remove/Install—Type B
Remove and Install Chopper Drive Idler Shaft
PowerCast™ Tailboard—Exploded View
Remove and Install PowerCast™ Tailboard Blades
Remove and Install Straw Spreader
Disassemble and Assemble Straw Spreader
Remove and Install Flex Residue Overshot Beater Gear Case
Disassemble and Assemble Flex Residue Overshot Beater Gear Case
Remove and Install Flex Residue Overshot Beater
Remove and Install Flex Residue Overshot Beater Wear Strips
Group 20: Conveyor Augers, Cleaning Fan and Chaffer and Sieve Frame
Specifications
Remove and Install Conveyor Auger Drive Shaft
Remove and Install Conveyor Augers
Remove and Install Conveyor Auger Trough
Remove and Install Conveyor Auger Slip Clutch
Remove and Install Conveyor Auger Bulkhead
Remove and Install Cleaning Fan Sheave And Bearing
Fan Drive Speed Control
Remove Cleaning Fan Drive
Disassemble and Assemble Cleaning Fan Drive Jackshaft
Install Cleaning Fan Drive
Adjust Fan Speed Actuator
Remove and Install Cleaning Fan
Remove and Install Cleaning Fan Blade Inserts
Remove and Install Chaffer/Sieve Frame Clevis—Self-Leveling Shoe
Remove and Install Chaffer Element
Remove and Install Chaffer/Sieve—Self-leveling Shoe
Remove and Install Sieve Element
Remove and Install Chaffer/Sieve Rear Channel Assembly—Self-Leveling Shoe
Remove and Install Remote Shoe Actuator Motor
Remove and Install Remote Shoe Actuator Motor—Self-Leveling Shoe
Remove and Install Chaffer/Sieve Tilt Actuator Motor—Self-Leveling Shoe
Remove and Install Front Chaffer Element
Remove and Install Front Chaffer Element—With Chaffer Extension
Remove and Install Chaffer Frame—Without Self-Leveling Shoe
Remove and Install Chaffer Frame—With Self-Leveling Shoe
Remove and Install Sieve Frame—Without Self-Leveling Shoe
Remove and Install Sieve Frame—With Self-Leveling Shoe
Remove and Install Shake Pan
Remove and Install Shoe Pitman Arms
Group 25: Tailings Elevator and Augers
Specifications
Remove and Install Tailings Paddle Chain
Remove and Install Tailings Paddle Chain Equipped With Active Tailings Return System
Remove and Install Tailings Paddle
Remove Lower Tailings Auger
Install Lower Tailings Auger
Remove Upper Tailings Auger
Remove Upper Tailings Auger Equipped With Active Tailings Return System
Install Upper Tailings Auger
Install Upper Tailings Auger Equipped With Active Tailings Return
Remove and Install Active Tailings Return Assembly
Disassemble and Assemble Active Tailings Return Assembly
Remove Tailings Elevator
Install Tailings Elevator
Remove and Install Tailings Elevator Equipped With Active Tailings Return System
Group 30: Primary Countershaft Gear Case
Specifications
Remove and Install Primary Countershaft Gear Case
Disassemble and Assemble Primary Countershaft Gear Case
Group 35: Header Electromagnetic Clutch
Specifications
Remove Header Electromagnetic Clutch
Header Electromagnetic Clutch Exploded View
Install Header Electromagnetic Clutch
Section 130: Grain Tank and Unloading System
Group 05: Grain Tank Cross Augers
Remove and Install Grain Tank Cross Augers—Style A
Remove and Install Grain Tank Cross Augers—Style B
Adjust Unloading Cross Auger Drive Chain
Group 10: Unloading Auger System Drives
Specifications
Remove and Install Unloading Auger Drive Belts
Remove and Install Unloading Auger Drive Countershaft
Group 15: Vertical Unloading Auger and Lower Gear Case
Specifications
Remove Vertical Auger Lower Gear Case and Vertical Auger
Remove Vertical Auger Lower Gear Case and Vertical Auger—Heavy Duty
Disassemble and Assemble Vertical Auger Lower Gear Case
Disassemble and Assemble Vertical Auger Lower Gear Case—Heavy Duty
Install Vertical Auger and Vertical Auger Lower Gear Case
Install Vertical Auger and Vertical Auger Lower Gear Case—Heavy Duty
Group 20: Horizontal Unloading Auger and Gear Case
Specifications
Inspection of Horizontal Unloading Auger
Horizontal Unloading Auger Exploded View—Style A
Horizontal Unloading Auger Exploded View—Style B
Remove and Install Unloading Auger Grain Saver Door
Remove Horizontal Auger
Install Horizontal Auger
Remove Horizontal Auger Gear Case
Unloading Auger Gear Case Exploded View—Style A
Unloading Auger Gear Case Exploded View—Style B
Disassemble and Assemble Horizontal Unloading Auger Gear Case
Install Horizontal Auger Gear Case
Remove Horizontal Unloading Auger Housing
Install Horizontal Unloading Auger Housing
Unloading Auger Elbow Exploded View—Style A
Unloading Auger Elbow Exploded View—Style B
Remove Horizontal Auger Elbow
Install Horizontal Auger Elbow
Remove Unloading Auger Charge Housing
Install Unloading Auger Charge Housing
Group 25: Clean Grain Elevator
Specifications
Adjust Clean Grain Elevator Chain
Remove and Install Clean Grain Paddle Chain
Remove and Install Clean Grain Paddle
Remove Clean Grain Elevator
Install Clean Grain Elevator
Remove and Install Clean Grain Elevator Gear Case
Disassemble and Assemble Clean Grain Elevator Gear Case
Remove and Install Clean Grain Loading Auger Assembly—Grain Tank Covers
Remove and Install Clean Grain Loading Auger Assembly—Grain Tank Extensions
Remove and Install Clean Grain Loading Auger
Replace Clean Grain Loading Auger Bearing
Remove and Install Lower Clean Grain Auger
Section 140: Engine Gear Case and Control Valve
Group 05: Engine Gear Case and Valve
Specifications
General Information
Remove and Install Engine Gear Case
Engine Gear Case Specifications
Remove and Install Rotor Variable Drive
Disassemble and Assemble Rotor Variable Drive
Remove and Install Rotor Variable Drive Shaft
Remove and Install Transfer Gear Case
Disassemble and Assemble Separator Drive Wet Clutch
Disassemble and Assemble Hydrostatic Gear Set
Set Hydrostatic Gearset Position
Preload Hydrostatic Gearset Bearings
Disassemble and Assemble Straw Chopper and Unloading Auger Drive
Set Separator Gearset Position
Preload Separator Gearset Bearings
Disassemble and Assemble Separator Drive
Preload Separator Drive Bearings
Set Separator Drive Gear Backlash
Disassemble and Assemble Hydrostatic Pump Drive
Preload Hydrostatic Pump Drive Bearings
Set Hydrostatic Pump Drive Gear Backlash
Disassemble and Assemble Oil Screen
Disassemble and Assemble Oil Trough
Remove and Install Dipstick Tube
Remove and Install Pressure Regulating Valve
Disassemble and Assemble Pressure Regulating Valve
Section 199: Dealer Fabricated Tools
Group 05: Dealer Fabricated Tools
DFRW20—Compressor Holding Fixture
DFHXT1—Split Ring Tool
DFHXT2—Hydraulic Cylinder Tool
DFHXT3—Swash Plate Holding Tool
DFHXT4—Split Ring Tool
DFHXT6—Park Brake Solenoid Power Lead
DFHXT7—Tracks Mid-Roller Hub Adapter Plate
DFHXT8—Tracks Rear Axle and Tension Axle Hub Adapter Plate
John Deere Combines S540, S550, S660, S670, S680, S690 Repair Service Technical Manual (TM803819)