Complete service technical manual with electrical wiring diagrams for John Deere 678 Hay and Forage Wrapping Baler, with workshop information to maintain, diagnose, repair, and service like professional mechanics.

John Deere Hay and Forage Wrapping Balers Models 678 workshop Diagnostic and 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.

TM3301 - John Deere 678 Hay and Forage Wrapping Baler All Inclusive Technical Manual (Diagnosis and Repair).PDF

Total Pages: 2,271 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
  Electrical System - Repair
      Connectors
      Sensors and Switches
      Actuators
      BaleTrak Plus Monitor
   Power Train
      Walterscheid Powerline
      Cam-Type Cut Out Clutch
      MaxiCut Precutter Gear Case
      Chain Tension
      Sprocket Alignment
   Braking System - Repair
   Hydraulic System - Repair
      Bale Density Control Valve
      Wrapping Valve
      Main Control Valve
      Hydraulic Cylinders
      Hydraulic Brake
      Hydraulic Motor Series
      OMP Hydraulic Motor Series
      OMS Hydraulic Motor Series
      MaxiCut Precutter Electro-Hydraulic Valve
      Coupler
   Hydraulic System - Adjustment
   Miscellaneous
      Wheel, Hub and Axle
      Bale Shape Indicator
      Tongue
      Body Frame
   Lubrication System - Repair
      Drive Chain Lubrication
      Automatic Greasing System (S.N. 089000-)
   Pickup Repair
   MaxiCut Precutter System
   Bale Chamber Rolls
   Net Tying
   Twine Tying
   Wrapping Table
      Table Drive
      Belt and Roll
   Wrapping Device
      Rubber Mat
      Bale Tilt
      Wrapping Arm
   Diagnostic Trouble Codes
   Troubleshooting
      Bale Density/Gate Control
      Wrapper Control
   Electrical System
      General Information
      Test Equipment
      Electrical System / Diagrams /Diagnostic
      - Diagrams for Road Light
      - BaleTrak Control
      -GreenStar Control
      Fuse Diagnosis
      Checking Lamp E101 (Optional)
      Checking Safety Arm Sensor S103 and Stop Button S101
      Checking Torn Film Sensor S104
      Checking Wrapping Arm Position Sensor S105, S106
      Checking Net Feeding Sensor S107
      Checking Gate Open Sensor S108
      Checking Gate Closed Sensor S109
      Checking Bale On Table Sensor S110
      Checking Wrapping Table Position Sensors S111 and S112
      Checking Table Positioning Sensor S113
      Checking Twine Tying Sensor S114 and Net Cut Sensor S4
      Checking Slow Speed Table Belt solenoid valve Y101 (Optional)
      Checking solenoid valve Y102 for Lowering Knives
      Checking solenoid valve Y103 for Raising Knives
      Checking Close Gate solenoid valve Y104, Y105
      Checking Table Forward Movement solenoid valve Y106
      Checking Table Backward Movement solenoid valve Y107
      Checking Fast Speed Arm Rotation solenoid valve Y108
      Checking Reverse/Regular Arm Rotation solenoid valve Y109/Y110
      Checking Slow Speed Table Movement solenoid valve Y111 and Buzzer H101
      Electrical System/Virtual Terminal Control
      Electrical Diagrams/Virtual Terminal Control
      Diagnostic Mode/Virtual Terminal Control
      Machine Setup/Virtual Terminal Control
      Software/Virtual Terminal Control
   Lubrication System - Operation and Tests
   Air Brake System - Operation and Tests
   Hydraulic Brake System - Operation and Tests
   Hydraulic System - Operation and Tests
   Net Tying - Operation and Tests
   Twine Tying - Operation and Tests
   Special Tools - Dealer-Fabricated

tm3301 - 678 Wrapping Baler

Table of Contents

Foreword

Section 05: Safety

Group 05: Safety Information

Prepare for Emergencies

Service Machine Safely

Avoid High-Pressure Fluids

Support Machine Properly

Wear Protective Clothing

Stay Clear of Rotating Drivelines

Service Machines Safely

Work in Clean Area

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Service Tires Safely

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Safety Information - Air Brake System

Section 10: General

Group 05: Baler Serial Numbers

Wrapping Baler Identification Number

Serial Number Plate Description

Historical Account

Group 10: GreenStar Component Identification

Identification Labels

GREENSTAR GREENSTAR is a trademark of Deere & Company Display

GREENSTAR GREENSTAR is a trademark of Deere & Company Mobile Processor

GREENSTAR GREENSTAR is a trademark of Deere & Company KeyCard

GREENSTAR GREENSTAR is a trademark of Deere & Company PC Data Storage Card

GREENSTAR GREENSTAR is a trademark of Deere & Company Controller

Group 15: Torques for Hardware

Metric Bolt and Screw Torque Values

Group 20: Lubrication

Gear Oil

Grease

Grease for Automatic Greasing System

Multiluber Chain Oil

Section 40: Electrical System — Repair

Group 05: Connectors

Special or Essential Tools

Electrical Connector Handling

Disconnecting Electrical Circuit

Insulated and Non-Insulated Connectors

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Male and Female Connectors

Connectors for Electronic Control Units

Harness Repair (Splice Broken or Cut Wire)

Harness Repair—Splice Connector

Group 10: Sensors and Switches

Sensors and Switches - Summary of References

Sensors and Switches - Specifications

BaleTrak BaleTrak is a trademark of Deere & Company Component Location (S.N. —088999)

GreenStar GreenStar is a trademark of Deere & Company Component Identification (S.N. —088999)

Virtual Terminal Component Identification (S.N. 089000—)

Adjust Oversize-Gate Switch S1 and Full-Size Bale Switch S3 (S.N. —078999)

Adjust Oversize-Gate Switch S1 and Full-Size Bale Switch S3 (S.N. 080000—)

Adjust Net Cut Switch S4 (S.N. —079999)

Adjust Net Cut Sensor S4 (S.N. 080000—)

Adjust Net Cut Sensor S4 for GreenStar Monitor (S.N. 080000—088999)

Adjust Baler Rotation Speed Sensor S6

Adjust Twine Pulley Sensors S7 and S8

Adjust MaxiCut MaxiCut is a trademark of Deere & Company Precutter Reverse Sensor S9

Adjust MaxiCut MaxiCut is a trademark of Deere & Company Precutter Knife Switches S10 and S11

Adjust Safety Arm Sensor S103

Adjust Main Film Sensor S104 (S.N. —039999)

Adjust Main Film Sensor S104 (S.N. 040000—)

Adjust Film Sensors L1 and L2 (S.N. 040000—)

Adjust Wrapping Arm Sensors S105 and S106

Adjust Net Feeding Sensor S107 (S.N. —079999)

Adjust Net Feeding Sensor S107 for GreenStar Monitor (S.N. 080000—088999)

Adjust Gate Position Sensors S108 and S109 (S.N. —088999)

Adjust Gate Opened Sensor S108 (S.N. 089000—)

Adjust Bale on Wrapping Table Sensor S110

Adjust Wrapping Table Position Sensors S111 and S112

Adjust Table Positioning Sensor S113 (S.N. —068999)

Adjust Table Positioning Sensor S113 (S.N. 070000—)

Adjust Twine Pulley Sensor S114 (S.N. —088999)

Group 15: Actuators

Other Material

Actuators - Specifications

Component Identification

Remove and Install Twine Arm Actuator M1

Remove and Install Net Arm Actuator M1 (S.N. 089000—)

Disassemble/Assemble Tying Actuator M1/M2

Group 50: BaleTrak Plus Monitor (S.N. —088999)

BaleTrak Plus Monitor (S.N. —088999) - Specifications

Replace BaleTrak EPROM

Disassembling BaleTrak Monitor

Assembling BaleTrak Monitor

Reprogramming BaleTrak Software

Section 50: Power Train

Group 10: Walterscheid Powerline

Specifications

Exploded-view of Powerline (S.N. —050996)

Exploded-view of Powerline (S.N. 050997—068999)

Exploded-view of Powerline (S.N. 070000— )

Repair Powerline

Group 20: Cam-Type Cut Out Clutch

Cam-Type Cut Out Clutch — Summary of References

Group 20A: Cam-Type Cut Out Clutch (S.N. —061888)

Other Material — Cam-Type Cut Out Clutch (S.N. —061888)

Specifications — Cam-Type Cut Out Clutch (S.N. —061888)

Disassembling Cam-Type Cut Out Clutch

Adjusting Cam-Type Cut Out Clutch

Exploded View of Cam-Type Cut Out Clutch (S.N. —061888)

Assembling Cam-Type Cut Out Clutch — Cam-Type Cut Out Clutch (S.N. —061888)

Group 20B: Cam-Type Cut Out Clutch (S.N.061889—)

Other Material — Cam-Type Cut Out Clutch (S.N.061889—)

Specifications — Cam-Type Cut Out Clutch (S.N.061889—)

Disassemble Cam-Type Cut Out Clutch

Adjust Cam-Type Cut Out Clutch

Exploded View of Cam-Type Cut Out Clutch

Assembling Cam-Type Cut Out Clutch

Group 30: MaxiCut Precutter Gear Case

MaxiCut Precutter Gear Case - Other Material

MaxiCut Precutter Gear Case - Specifications

Removing Gear Case

Exploded View of MAXICUT MAXICUT is a trademark of Deere & Company Precutter Gear Case

Disassembling Gear Case

Inspect Gear Case

Assemble Gear Case

Install Gear Case

Group 35: Chain Tension

Chain Tension - Specifications

Adjusting Roll Drive Chains

Adjust MaxiCut MaxiCut is a trademark of Deere & Company Precutter Pickup Drive Chains

Adjusting MAXICUT MAXICUT is a trademark of Deere & Company Precutter Main Drive Chain

Adjust Wrapping Table Roll Drive Chain

Adjust Wrapping Table Drive Chain (S.N. —068999)

Adjust Wrapping Table Drive Chains (S.N. 070000—088999)

Adjust Wrapping Table Drive Chains (S.N. 089000—089999)

Adjust Wrapping Table Drive Chains (S.N. 090000—)

Group 40: Sprocket Alignment

Sprocket Alignment - Specifications

Check and Adjust Sprocket Alignment

Section 60: Braking System — Repair

Group 05: Air Brakes

Specifications

Preliminary Check

General Information

Air Brake Connection Lines—Exploded View

Drain Air Brake Reservoir

Clean Air Filters

Install Plug-in Connections

Remove Reservoir

Install Reservoir

Remove Relay Emergency Valve

Install Relay Emergency Valve

Remove Brake Cylinder

Adjust Air Brake Cylinder Clevis

Install Brake Cylinder

Group 10: Hydraulic Brakes

Specifications

Hydraulic Brake Cylinders

Remove Brake Cylinder

Disassemble and Assemble Hydraulic Brake Cylinder

Adjust Hydraulic Brake Cylinder Clevis

Install Hydraulic Brake Cylinder

Group 15: Brake Shoe and Drum

Specifications

Adjust Brake Shoes

Adjust Brake Lever

Section 70A: Hydraulic System — Repair

Group 05: Safety

Recommendations

Safety - Avoid High-Pressure Fluids

Group 10: Bale Density Control Valve

Bale Density Control Valve — Summary of References

Group 10A: Bale Density Control Valve (S.N. —088999)

Removing and Installing Bale Density Control Valve

Disassembling Bale Density Control Valve

Assembling Bale Density Control Valve

Check Condition of Valve Seats and Poppets (S.N. —088999)

Adjusting Bale Density Control Valve

Group 10B: Bale Density Control Valve (S.N. 089000—)

Remove and Install Bale Density Control Valve

Disassemble Bale Density Control Valve

Assemble Bale Density Control Valve (S.N. 089000—089999)

Assemble Bale Density Control Valve (S.N. 090000—)

Check Condition of Valve Seats and Poppets

Adjust Bale Density

Group 12: Wrapping Valve

Wrapping Valve — Summary of References

Group 12A: Wrapping Valve (S.N. —088999)

Wrapping Valve (S.N. —088999) - Specifications

Disassemble and Assemble Wrapping Table Auxiliary Control Valve

Disassemble and Assemble Knife Auxiliary Control Valve

Disassemble and Assemble Half Speed Wrapping Table Control Valve

Disassemble and Assemble Table Transfer Auxiliary Control Valve

Exploded-view of Rotating Hydraulic Arm Valve (S.N. —080710)

Disassemble and Assemble Rotating Hydraulic Arm Valve (S.N. 080711—088999)

Group 12B: Wrapping Valve (S.N. 089000—)

Wrapping Valve (S.N. 089000—) - Specifications

Disassemble and Assemble Wrapping Knife Auxiliary Control Valve

Disassemble and Assemble Wrapping Table Transfer Relief Valve

Disassemble and Assemble Wrapping Table and Rotating Arm Control Valve

Group 14: Main Control Valve

Main Control Valve — Summary of References

Group 14A: Main Control Valve (S.N. —088999)

Main Control Valve (S.N. —088999) - Specifications

Identification View

Exploded View of Main Control Valve

Disassemble Main Control Valve

Assemble Main Control Valve

Remove and Install Load Sensing Restrictor (S.N. —088999)

Remove and Install Pressure Reduction Valve (S.N. —088999)

Remove and Install Valve Spool (S.N. —088999)

Remove and Install Valve Electrical Module

Group 14B: Main Control Valve (S.N. 089000—)

Main Control Valve (S.N. 089000—) - Specifications

Identification View of Main Valve

Disassemble and Assemble Open-Close Center Valve

Disassemble and Assemble Main Control Valve

Remove and Install Load Sensing Restrictor (S.N. 089000—)

Remove and Install Pressure Reduction Valve

Remove and Install Valve Spool

Remove and Install Main Valve Electrical Module

Group 20: Hydraulic Cylinders

Other Material

Hydraulic Cylinders - Specifications

Removing and Installing Gate Cylinder

Disassemble and Assemble Gate Cylinder DC55055

Disassemble and Assemble Gate Cylinder DC205095 and DC206233

Disassemble and Assemble MaxiCut MAXICUT is a trademark of Deere & Company Precutter Pickup Lift Cylinder (DC47437)

Disassemble and Assemble MaxiCut MaxiCut is a trademark of Deere & Company Precutter Pickup Lift Cylinder (DC203575)

Disassemble and Assemble MaxiCut MaxiCut is a trademark of Deere & Company Precutter Knife Cylinder

Disassemble and Assemble Gear Case Reverse Cylinder

Group 25: Hydraulic Brake

Specifications

Disassembling and Assembling Hydraulic Brake

Group 30: Hydraulic Motor Series

Hydraulic Motor Series — Summary of References

Group 30A: OMP Hydraulic Motor Series

OMP Hydraulic Motor Series

Essential Tools — OMP Hydraulic Motor Series

Specifications — OMP Hydraulic Motor Series

Disassembling Hydraulic Motor

Inspect Hydraulic Motor

Assembling Hydraulic Motor

Group 30B: OMS Hydraulic Motor Series

OMS Hydraulic Motor Series

Essential or Recommended Tools

OMS Hydraulic Motor Series - Specifications

Disassemble Hydraulic Motor

Inspect OMS Hydraulic Motor

Assemble Hydraulic Motor

Group 35: MaxiCut Precutter Electro-Hydraulic Valve

Specifications

Remove and Install MaxiCut MaxiCut is a trademark of Deere & Company Precutter Valve

Bleed MaxiCut MaxiCut is a trademark of Deere & Company Precutter Circuit

Identification View of MAXICUT MAXICUT is a trademark of Deere & Company Precutter Valve

Disassembling and Assembling MAXICUT MAXICUT is a trademark of Deere & Company Precutter Valve

Group 45: Coupler

Coupler - Specifications

Cleaning Filter

Section 70B: Hydraulic System — Adjustment

Group 05: Safety

Recommendations

Group 10: Adjustment

Adjustment — Summary of References

Group 10A: Adjustment (S.N. —088999)

Adjustment (S.N. —088999) - Specifications

Adjust the Tractor SCV Flow (S.N. —088999)

Set Hydraulic Circuit of Wrapping Baler

Adjust Load Sense Booster Valve (if Equipped)

Adjust Wrapping Arm Speeds

Adjust Wrapping Table Speeds

Adjust Gate Speed

Group 10B: Adjustment (S.N. 089000—)

Adjust the Tractor SCV Flow

Select Hydraulic Circuit

Section 80: Miscellaneous

Group 05: Wheel, Hub and Axle

Other Material

Specifications

Exploded View of Wheel Hub (without Brake)

Disassembling Wheel Hub (without Brake)

Assembling Wheel Hub (without Brake)

Exploded View of Wheel Hub (with Brake)

Disassembling Wheel Hub (with Brake)

Assembling Wheel Hub (with Brake)

Exploded View of Axle

Remove Axle

Inspect Axle

Install Axle

Group 15: Bale Shape Indicator

Adjusting Bale Shape Indicator Straps

Group 20: Tongue

Specifications

Assemble Tongue

Group 25: Body Frame

Specifications

Checking Frame Fittings

Adjusting the Wrapping Arm Position

Section 85: Lubrication System — Repair

Group 05: Drive Chain Lubrication

Drive Chain Lubrication — Summary of References

Group 05A: Drive Chain Lubrication (S.N. —049999)

Removing and Installing Filter

Remove and Install Metering Valve

Disassemble and Assemble Pump

Adjust Lubrication Pump Flow

Adjust Chain Oiling System Brush Flow

Adjust Brush

Bleed the Circuit

Group 05B: Drive Chain Lubrication (S.N. 050000—)

Adjust Oil Flow

Bleed Chain Oiling System Pump

Adjusting Brushes

Removing and Installing Hoses

Group 20: Automatic Greasing System (S.N. 089000—)

Exploded-View of Automatic Greasing Pump

Disassemble Pump Element

Assemble Pump Element

Bleed Automatic Greasing System Pump

Section 100A: Pickup Repair

Group 15: 2.00 m (6 ft 7 in.) Pickup

2.00 m (6 ft 7 in.) Pickup - Specifications

Repair the Pickup Cylinder

Section 100B: MaxiCut Precutter System

Group 05: Adjustment

Specifications

MaxiCut MaxiCut is a trademark of Deere & Company Precutter Rotor and Bearing—Cross-Sectional View

Adjusting Scrapers

Section 120: Bale Chamber Rolls

Group 20: Rolls and Bearings

Other Material

Specifications

Service Rolls Safely

Baler Roll Numbering

Rolls and Bearings—Cross-Sectional View

Removing Roll No. 1 and its Bearings

Removing Rolls No. 2 to 9 and their Bearings

Removing Roll No.10 and its Bearings

Removing Rolls No.11, 14, 17 and their Bearings

Removing Roll No.12 and its Bearings

Removing Roll No.13, 15, 16 and their Bearings

Install Roll No.1 and its Bearings

Install Rolls No. 2 to 9 and their Bearings

Install Rolls No. 10, 11, 14, 17 and their Bearings

Install Roll No. 12 and its Bearings

Install Rolls No. 13, 15, 16 and their Bearings

Group 25: Scraper of Roll

Adjust Roll (NR 12) Scraper (S.N. 061053— )

Adjusting Roll (NR 13) Scraper

Section 130A: Net Tying

Group 15: Repair — Net Tying

Repair — Standard Net Tying — Summary of References

Group 15A: Repair — Standard Net Tying (S.N.— 079999)

Repair — Standard Net Tying (S.N.— 079999) — Specifications

Exploded View of Net Tying System

Disassemble Net Tying System

Assemble Net Tying System

Replacing Bearings in Roll

Remove and Install Net Knife — Standard Net Tying (S.N.— 079999)

Sharpen Net Knife

Remove and Install Rear Net Guide

Remove Front Net Guide

Install Front Net Guide

Remove Net Feed Roll Drive Belt

Install Net Feed Roll Drive Belt

Removing Net Wrapped Around Feed Rolls

Check and Adjust Galvanized Net Feed Roll No.18 Radial Play

Check and Adjust Galvanized Net Feed Roll No.18 Bearing

Adjust Net Feed Roll Pressure

Adjust Net Knife Arm Stop

Adjust Net Feed Roll Drive Belt Tension

Check Net Feed Roll Brake

Adjusting Net Lateral Guide

Group 15B: Repair — CoverEdge Net Tying (S.N. 080000—)

Repair — Specifications

Check Galvanized Roll Flatness

Adjust Counter-Knife Position

Adjust Plastic Rollers

Adjust Net Actuator Position

Adjust Rubber Roll Brake

Adjust Net Tying Drive Belt Tension

Remove and Install Net Tying Drive Belt

Remove and Install Net Knife

Remove Net Wrapped Around Feed Rolls

Section 130B: Twine Tying

Group 15: Repair — Twine Tying

Repair — Twine Tying - Specifications

Exploded View of Twine Tying System

Adjusting Double Arm Twine Tying Geometry

Adjust Double Arm Twine Tying Starting Point

Adjusting Flaps

Adjust Twine Cutter

Adjust Tension Plates

Adjust Pulley Supports

Adjusting Twine Guides

Section 140: Wrapping Table

Group 05: Table Drive

Exploded View of Table Drive Shaft

Group 10: Belt and Roll

Other Material

Specifications

Remove Front Roll and its Bearings

Install Front Roll and its Bearings

Remove Rear Roll and its Bearings

Install Rear Roll and its Bearings

Replace Table Belt

Adjust Table Belt Tension

Exploded View of Steep Slope Device

Section 150: Wrapping Device

Group 10: Rubber Mat

Specifications

Exploded View of Rubber Mat

Adjusting Rubber Mat Spring

Group 15: Bale Tilt

Adjust Bale Tilt Springs (S.N. 070000— )

Group 20: Wrapping Arm

Specifications

Check Wrapping Arm Fittings

Adjust Wrapping Arm Target Plate

Adjust Safety Arm Tension

Section 211: Diagnostic Trouble Codes

Group 05: Description

What is a DTC?

Section 211A: Diagnostic Trouble Codes — GreenStar

Group 05: Description

Diagnostic Trouble Codes for Wrapping Baler

Recent Problems Menu

Group 10: Wrapping Baler Diagnostic Trouble Code List

WB.100 - Wrong Display Version

WB.102 - Lost Display Access

WB.104 - Unexpected GSD Start-up

WB.260 - Output Overload

WB.302 - Open the gate?

WB.303 - The table is stalled!

WB.304 - The table does not move

WB.305 - Unload the bale?

WB.306 - No bale on table

WB.307 - Wrapping arm speed too slow!

WB.308 - Wrapping arm speed too fast!

WB.309 - Gate always open

WB.310 - Gate always closed

WB.311 - Gate neither closed nor open (ajar)

WB.312 - Arms still turning

WB.313 - Torn film or roll empty

WB.314 - Dispenser safety switch

WB.315 - Arms do not turn

WB.316 - Wrapping sensor 1 OUT

WB.317 - Wrapping sensor 2 OUT

WB.318 - Components will move

WB.319 - Clear data

WB.320 - Both films are torn

WB.321 - Table is in an unknown position

WB.322 - Arms are in an unknown position

WB.323 - Safety devices are engaged

WB.324 - There is a bale on the table

Group 15: Display Diagnostic Trouble Code List

Display Diagnostic Trouble Code List

Section 211B: Diagnostic Trouble Codes — BaleTrak

Group 05: Description

Read Me First!

Group E00X: Battery Voltage

E001 - Erratic Supply Voltage

E002 - Tension Below or Equal to 11,2 V

E003 - Tension Over or Equal to 16 V

Functional Schematic of Power Supply

Group E20X: Twine Actuator M1

E201 - Open Circuit

E202 - Faulty Actuator

E203 - Resistive Power Line

E204 - Shorted Circuit

E205 - Grounded Circuit

Functional Schematic of Twine Tying Actuator M1

Group E21X: Net Actuator M2

E211 - Open Circuit

E212 - Faulty Actuator

E213 - Resistive Power Line

E214 - Shorted Circuit

E215 - Grounded Circuit

Functional Schematic of Net Tying Actuator M2

Group E23X: Pick up Valve Y4

E231 - Open Circuit

E232 - Grounded Circuit

E233 - Shorted Circuit

Functional Schematic of Pickup Valve Function Y4

Group E24X: Knife Valve Y3

E241 - Open Circuit

E242 - Grounded Circuit

E243 - Shorted Circuit

Functional Schematic of Knife Valve Function Y3

Group E25X: Reverser Valve Y2

E251 - Open Circuit

E252 - Grounded Circuit

E253 - Shorted Circuit

Functional Schematic of Reverser Valve Function Y2

Group E31X: Gear Case RPM Sensor S6

E311 - Open Circuit

E312 - Speed Below the Minimum Value

E313 - Speed Over the Maximum Value

Functional Schematic of Gear Case RPM Sensor S6

Group E32X: Twine Pulley Sensor S7/S8

E321 - Twine Not Detected

E322 - Twine Not Cut

Functional Schematic of Twine Pulley Sensors S7/S8

Group E40X: Net Switch S4

Net Switch S4 — Summary of References

Group E40Xa: Net Switch S4 (S.N. —079999)

E401 - Always Opened

E402 - Always Closed

Functional Schematic of Net Switch S4 (S.N. —079999)

Group E40Xb: Net Sensor S4 (S.N. 080000—)

E401 - Net Not Detected

E402 - Net Not Cut

Functional Schematic of Net Sensor S4 (S.N. 080000—)

Group E41X: Right Gate Switch S1

E411 - Always Opened

E412 - Always Closed

Functional Schematic of Right Gate Switch S1

Group E43X: Full-Size Bale Switch S3

E432 - Always Closed

Functional Schematic of Full-Size Bale Switch S3

Group E60X: EPROM

E601 - User Table, All User Banks Corrupted

E602 - User Table, One User Bank Corrupted

E603 - Factory Table, All Factory Banks Corrupted

E604 - Factory Table, One Factory Bank Corrupted

E605 - EPROM or Software Failure

Section 211C: Diagnostic Trouble Codes — Virtual Terminal

Group 05: Description

Warning Screens

Group 10: Diagnostic Trouble Code List

Diagnostic Trouble Code List

Section 212: Troubleshooting

Group 10: Bale Density/Gate Control — Troubleshooting

Bale Density/Gate Control — Troubleshooting — Summary of References

Group 10A: Bale Density/Gate Control — Troubleshooting (S.N. —088999)

Diagnose Hydraulic Functions (S.N. —088999)

Group 10B: Bale Density/Gate Control — Troubleshooting (S.N. 089000—)

Diagnose Hydraulic Functions (S.N. 089000—)

Group 20: Wrapper Control — Troubleshooting

Wrapper Control — Troubleshooting — Summary of References

Group 20A: Wrapper Control — Troubleshooting (S.N. —088999)

Diagnose Wrapping Baler (S.N. —088999)

Group 20B: Wrapper Control — Troubleshooting (S.N. 089000—)

Diagnose Wrapping Baler (S.N. 089000—)

Section 240: Electrical System

Group 05: General Information

Electrical Circuit Malfunctions

Open Circuit

Grounded Circuit

Shorted Circuit

How to Read a Functional Schematic

How to Read a Wiring and Harness Diagram

Symbols in System Diagrams

Component Identification Table

Group 06: Test Equipment

Special or Essential Tools

Group 10: Electrical System Diagrams for Road Light

Electrical System Diagrams for Road Light — Summary of References

Group 10A: Electrical System Diagrams for Road Light (S.N. —070407)

Wiring Harness Identification (S.N. —070407)

Component Identification — Road Lights

Component Location — Road Lights

Wiring Diagram — Road Lights

Group 10B: Electrical System Diagrams for Road Light (S.N. 070408—)

Wiring Harness and Wiring Diagram — Road Lights

Group 30: Electrical System/BaleTrak Control

Specifications

BaleTrak Plus Monitor

BaleTrak Plus Monitor Keyboard Description

LCD Screen Description

Warning Pictograms

Operational Information

Group 30A: Electrical Diagrams/BaleTrak Control

Electrical Diagrams/BaleTrak Control — Summary of References

Group 30A1: Electrical Diagrams/BaleTrak Control (S.N. —070407)

Wiring Harness Identification — BaleTrak (S.N. —070407)

Component Identification — BaleTrak (S.N. —070407)

Component Location of Main Wiring Harness W2

Wiring Diagram of Main Wiring Harness W2

Component Location of MAXICUT MAXICUT is a trademark of Deere & Company Precutter Wiring Harness W3

Wiring Diagram of MAXICUT MAXICUT is a trademark of Deere & Company Precutter Wiring Harness W3

Component Location of Battery Wiring Harness W1

Wiring Diagram of Battery Wiring Harness W1

Functional Schematic (Part 1) — BaleTrak (S.N. —070407)

Functional Schematic (Part 2) — BaleTrak (S.N. —070407)

Group 30A2: Electrical Diagrams / BaleTrak Control (S.N. 070408—088999)

Wiring Harness Identification — Baletrak (S.N. 070408—088999)

Component Identification — BaleTrak (S.N. 070408—088999)

Component Location of Wiring Harness W2, W3, W4, W5 and W6

Wiring Diagram of Wiring Harness and Road Lights W2, W5 and W6

Wiring Diagram of MAXICUT Precutter Wiring Harness W3 — Baletrak (S.N. 070408—088999)

Wiring Diagram of Rear Road Lights W4 — BaleTrak (S.N. 070408—088999)

Component Location and Wiring Diagram of Battery Wiring Harness W1

Functional Schematic (Part 1) — BaleTrak (S.N. 070408—088999)

Functional Schematic (Part 2) — Baletrak (S.N. 070408—088999)

Group 30B: Diagnostic Modes/BaleTrak Control

Safety

Essential Tools

Diagnostic Mode: User Parameters

Channel 001: Reset to Factory Default Settings

Channel 002, 003, 004

Channel 005: Not Used

Channel 006 and 007: Calibration of Bale Shape Potentiometer

Channel 008: Measurement units

Channel 009

Channel 010, 011: Not Used

Channel 012: Test of Net Cut Switch (S.N. —079999)

Channel 012: Test of Net Cut Sensor (S.N. 080000—)

Channel 013: Test of Full-Size Bale Switch

Channel 014: Test of Oversize-Gate Switch

Channel 015, 016: Not Used

Channel 017: Speed of Gear Case

Channel 018: Test of Actuator Current Consumption

Channel 019: Voltmeter

Channel 020: Test of LCD Screen

Channel 021: Maximum Actuator Current Consumption

Channel 022: Test of Twine Pulley Sensor 1

Channel 023: Test of Twine Pulley Sensor 2

Channel 024: Test of MaxiCut MaxiCut is a trademark of Deere & Company Precutter Reverse Sensor

Channel 025: Test of MaxiCut MaxiCut is a trademark of Deere & Company Precutter Knife Switches

Channel 026, 027, 028: Not Used

Channel 029: Calibration of Double Arm Twine Tying Actuator

Channel 030: Twine Actuator Stroke

Channel 031: Not used

Channel 032

Diagnostic Mode: Factory Parameters

Channel 201: Baler Model

Channel 202: Twine Tying Device

Channel 203: Net Tying Mode Configuration

Channel 204: Not Used

Channel 205: Gear Case RPM Sensor

Channel 206: Not Used

Channel 207: Calibration of Gear Case RPM Sensor

Channel 208: Not Used

Channel 209: MaxiCut MaxiCut is a trademark of Deere & Company Precutter Device

Channel 210: Twine Pulley Sensors

Channel 211: Bale Shape Device

Channel 212 : Adjust Speed of Net Actuator

Channel 213 : Adjust Drop-Off Time of Net Actuator

Channel 214 : Adjust Acceleration Ramp of Net Actuator

Diagnostic Mode: Diagnostic Channels

Channel 301/3/5 and 302/4/6: Diagnostic Trouble Code (DTC) and Bale Counter Memory

Channel 307: Minutes Counter

Channel 308: Global Hours Counter

Channel 309: Lowest Battery Voltage Level Recorded

Channel 310: Highest Battery Voltage Level Recorded

Channel 311: Controller Software Version

Channel 312: Total Bale Counter

Group 40: Electrical System/GreenStar Control

GreenStar Monitor

GreenStar Monitor Board Description

INFO Mode Functions

RUN Mode Functions (Factory Settings)

Wrapping Process Description with GreenStar Control

Position Wrapping Arms to Start a Wrapping Cycle

Position Wrapping Table to Start a Wrapping Cycle

Group 40A: Electrical Diagrams/GreenStar Control

Section Identification in Functional Schematics

Wiring Harness Identification

Component Identification — GreenStar

Component Location of Main and Auxiliary Wiring Harnesses W101, W102, W104 and W110

Wiring Diagram of Main and Auxiliary Wiring Harnesses W101, W102, W104 and W110

Component Location of Sensor and Switch Wiring Harnesses W103, W105, W106, W107, W108, W109, W111 and W112

Wiring Diagram of Sensor and Switch Wiring Harnesses W103, W105, W106, W107, W108, W109, W111 and W112 (S.N. —079999)

Wiring Diagram of Sensor and Switch Wiring Harnesses W103, W105, W106, W107, W108, W109, W111 and W112 (S.N. 080000—)

Component Location of GreenStar Cab Harness W113

Wiring Diagram of Greenstar Cab Harness W113

Functional Schematic (Part 1)

Functional Schematic (Part 2)

Functional Schematic (Part 3)

Functional Schematic (Part 4) (S.N. —079999)

Functional Schematic (Part 4) (S.N. 080000—)

Functional Schematic (Part 5) (S.N. —079999)

Functional Schematic (Part 5) (S.N. 080000—)

Functional Schematic (Part 6)

Group 40B: Diagnostic Mode/GreenStar Control

Enter Diagnostic Functions (GreenStar)

Enter Recent Problem List (GreenStar)

Test Sensors (GreenStar)

Test Electro-Hydraulic Components (GreenStar)

Group 40C: Machine Setup/GreenStar Control

Enter Machine Settings (GreenStar)

SETUP Mode Functions

Enter Machine Setup Pages

SETUP Machine Mode Functions

Set Knife Timing

Set Slow Speed Distances

Set Table Transfer Distances

Set Gate Delay

Set Bale Ejection Timing

Set Gate Close Pressure Timing

Set Sender Parameters (S.N. —068999)

Set Sender Parameter (S.N. 070000— )

Select Slow Arms at Film Release

Set Knife Raising

Select 50/50 Valve Option

Set Default Values

Group 40D: Software/GreenStar Control

Software Version

Loading New Wrapping Baler Software

Loading Wrapping Baler Software Language

Group 40I: Checking GreenStar Electrical Power System

Theory of operation

Checking Greenstar Electrical Power System

Group 40J: Fuse Diagnosis

Fuse Diagnosis

Group 40K: Checking Lamp E101 (Optional)

Theory of operation

Component Identification

Check Lamp E101 (optional)

Functional Schematic of Lamp E101 (Optional)

Group 40L: Checking Safety Arm Sensor S103 and Stop Button S101

Theory of operation

Component Identification

Check Safety Arm Sensor S103 and Stop Button S101

Functional Schematic of Safety Arm Sensor S103 and Stop Button S101

Group 40M: Checking Torn Film Sensor S104

Theory of operation

Component Identification

Check Torn Film Sensor S104

Functional Schematic of Torn Film Sensor S104

Group 40N: Checking Wrapping Arm Position Sensor S105

Theory of operation

Component Identification

Check Wrapping Arm Position Sensor S105

Functional Schematic of Wrapping Arm Position Sensor S105

Group 40O: Checking Wrapping Arm Rotation Sensor S106

Theory of operation

Component Identification

Check Wrapping Arm Rotation Sensor S106

Functional Schematic of Wrapping Arm Rotation Sensor S106

Group 40P: Checking Net Feeding Sensor S107

Theory of operation

Component Identification

Check Net Feeding Sensor S107 (S.N. —079999)

Functional Schematic of Net Feeding Sensor S107 (S.N. —079999)

Functional Schematic of Net Feeding Sensor S107 (S.N. 080000—088999)

Group 40Q: Checking Gate Open Sensor S108

Theory of operation

Component Identification

Check Gate Open Sensor S108

Functional Schematic of Gate Open Sensor S108

Group 40R: Checking Gate Closed Sensor S109

Theory of operation

Component Identification

Check Gate Closed Sensor S109

Functional Schematic of Gate Closed Sensor S109

Group 40S: Checking Bale On Table Sensor S110

Theory of operation

Component Identification

Check Bale On Table Sensor S110

Functional Schematic of Bale On Table Sensor S110

Group 40T: Checking Wrapping Table Position Sensors S111 and S112

Theory of operation

Component Identification

Check Wrapping Table Position 1 Sensor S111

Check Wrapping Table Position 2 Sensor S112

Functional Schematic of Wrapping Table Position 1 and 2 Sensors S111 and S112

Group 40V: Checking Table Positioning Sensor S113

Theory of operation

Component Identification

Check Table Positioning Sensor S113

Functional Schematic of Table Positioning Sensor S113

Group 40W: Checking Twine Tying Sensor S114 and Net Cut Sensor S4

Theory of operation

Component Identification

Check Net Cut Switch S4 (S.N. —079999)

Check Twine Tying Sensor S114

Functional Schematic of Twine Tying Sensor S114 and Net Cut Switch S4 (S.N. —079999)

Functional Schematic of Twine Tying Sensor S114 and Net Cut Sensor S4 (S.N. 080000—088999)

Group 40X: Checking Slow Speed Table Belt solenoid valve Y101 (Optional)

Theory of operation

Component Identification

Check Slow Speed Table Belt Rotation solenoid valve Y101

Functional Schematic of Slow Speed Table Belt Rotation Electrovalve Y101

Group 40Y: Checking solenoid valve Y102 for Lowering Knives

Theory of operation

Component Identification

Check solenoid valve Y102 for Lowering Knives

Functional Schematic of Electrovalve Y102 for Lowering Knives

Group 40Z: Checking solenoid valve Y103 for Raising Knives

Theory of operation

Component Identification

Check solenoid valve Y103 for Raising Knives

Functional Schematic of Electrovalve Y103 for Raising Knives

Group 40AA: Checking Close Gate solenoid valve Y104

Theory of operation

Component Identification

Check Close Gate solenoid valve Y104

Functional Schematic of Close Gate Electrovalve Y104

Group 40AB: Checking Open Gate solenoid valve Y105

Theory of operation

Component Identification

Check Open Gate solenoid valve Y105

Functional Schematic of Open Gate Electrovalve Y105

Group 40AC: Checking Table Forward Movement solenoid valve Y106

Theory of operation

Component Identification

Check Table Forward Movement solenoid valve Y106

Functional Schematic of Table Forward Movement Electrovalve Y106

Group 40AD: Checking Table Backward Movement solenoid valve Y107

Theory of operation

Component Identification

Check Table Backward Movement solenoid valve Y107

Functional Schematic of Table Backward Movement Electrovalve Y107

Group 40AE: Checking Fast Speed Arm Rotation solenoid valve Y108

Theory of operation

Component Identification

Check Fast Speed Arm Rotation solenoid valve Y108

Functional Schematic of Fast Speed Arm Rotation Electrovalve Y108

Group 40AF: Checking Reverse Arm Rotation solenoid valve Y109

Theory of operation

Component Identification

Check Reverse Arm Rotation solenoid valve Y109

Functional Schematic of Reverse Arm Rotation Electrovalve Y109

Group 40AG: Checking Regular Arm Rotation solenoid valve Y110

Theory of operation

Component Identification

Check Regular Arm Rotation solenoid valve Y110

Functional Schematic of Regular Arm Rotation Electrovalve Y110

Group 40AH: Checking Slow Speed Table Movement solenoid valve Y111 and Buzzer H101

Theory of operation

Component Identification

Check Slow Speed Table Movement solenoid valve Y111 and Buzzer H101

Functional Schematic of Slow Speed Table Movement Electrovalve Y111 and Buzzer H101

Group 50: Electrical System/Virtual Terminal Control

Main Page Display Description

Softkey Designation

Counter Function

Wrapping Process Description with Virtual Terminal Control

Place Wrapping Arms in Home Position

Place Wrapping Table in Home Position

Group 50A: Electrical Diagrams/Virtual Terminal Control

Section Identification in Functional Schematics — Virtual Terminal

Wiring Harness Identification—Virtual Terminal

Component Identification — Virtual Terminal

Component Location of Main and Auxiliary Wiring and Road Lights Harnesses W5, W6, W7, W101 and W107 (Right-Hand Side View)

Component Location of Main and Auxiliary Wiring and Road Lights Harnesses W101, W103, W105, W106, W110, W111 and W112 (Left-Hand Side View)

Wiring Diagram of Wiring and Road Lights Harnesses W7, W101, W107 and W110 (Part 1)

Wiring Diagram of Wiring and Road Lights Harnesses W7, W101, W107 and W110 (Part 2)

Wiring Diagram of Wiring and Road Lights Harnesses W103, W105, W106, W111 and W112

Component Location of MaxiCut MaxiCut is a trademark of Deere & Company Precutter Wiring Harness W3 (S.N. 089000—)

Wiring Diagram of MaxiCut MaxiCut is a trademark of Deere & Company Precutter Wiring Harness W3 (S.N. 089000—)

Component Location of Virtual Terminal Cab Harness W113

Wiring Diagram of Virtual Terminal Cab Harness W113

Functional Schematic (Part 1) — Virtual Terminal

Functional Schematic (Part 2) — Virtual Terminal

Functional Schematic (Part 3) — Virtual Terminal

Functional Schematic (Part 4) — Virtual Terminal

Functional Schematic (Part 5) — Virtual Terminal

Functional Schematic (Part 6) — Virtual Terminal

Group 50B: Diagnostic Mode/Virtual Terminal Control

Access Diagnostic Functions

Diagnostic Function

Recent Problems List

Test Tractor Battery Voltage

Test Sensors

Test Electro-Hydraulic Components

Test Actuator Electrical Consumption

Group 50C: Machine Setup/Virtual Terminal Control

Access Machine Settings

Setting Function

Enter Advanced Machine Settings

Advanced Machine Setting Function

Set Wrapping Knife Opening

Set Table Transfer Distance

Set Baler Rotation Speed Pulses

Set Tying Device

Set Auto Lube Device

Set Wrapping Table Sensor Parameters

Set Bale Rotation Speed

Set Default Values

Run Continuous

Set Wrapping Table Transfer Parameters

Set Wrapping Arm Speed Parameters

Calibration of Twine Actuator

Calibration of Net Actuator

Group 50D: Software/Virtual Terminal Control

Software Version

Section 250: Lubrication System — Operation and Tests

Group 05: Chain Lubrication — Theory of Operation

Chain Lubrication — Theory of Operation — Summary of References

Group 05A: Chain Lubrication — Theory of Operation (S.N. —049999)

Automatic Lubrication System (S.N. —049999)

Lubrication System Pump (S.N. —049999)

Main Oil Reservoir

Metering Valve

Group 05B: Chain Lubrication — Theory of Operation (S.N. 050000—)

Automatic Lubrication System

Lubrication System Pump

Group 06: Chain Lubrication — Component Location

Chain Lubrication — Component Location — Summary of References

Group 06A: Chain Lubrication — Component Location (S.N. —049999)

Brief Description

Component Location for Pickup With MaxiCut MaxiCut is a trademark of Deere & Company Precutter (S.N. —049999)

Group 06B: Chain Lubrication — Component Location (S.N. 050000—)

Component Location for Pickup With MaxiCut MaxiCut is a trademark of Deere & Company Precutter

Group 07: Chain Lubrication — Troubleshooting

Chain Lubrication — Troubleshooting — Summary of References

Group 07A: Chain Lubrication — Troubleshooting (S.N. —049999)

Diagnose Malfunctions

Group 07B: Chain Lubrication — Troubleshooting (S.N. 050000—)

Diagnose Chain Oil Malfunctions

Group 08: Chain Lubrication — Diagnostic and Test Procedure (S.N. —049999)

Test Sequence

Group 20: Automatic Greasing System — Theory of Operation

Automatic Greasing System—Principle

Group 22: Automatic Greasing System — Troubleshooting

Automatic Greasing System—Troubleshooting

Group 23: Automatic Greasing System — Diagnostic and Test Procedure

Check Automatic Greasing System

Section 260A: Air Brake System — Operation and Tests

Group 05: Safety

Working on the Air Brake System

Group 20: Air Brake System — Description

Description and Diagram

Group 21: Air Brake System — Tests

Essential Tools

Specifications

Operational Check

Check for Leaks at Brake Circuit

Check the Braking Pressure

Check Pilot Line Pressure

Section 260B: Hydraulic Brake System — Operation and Tests

Group 05: Safety

Safety - Avoid High-Pressure Fluids

Wear Protective Clothing

Group 20: Hydraulic Brake System — Description

Description and Diagram

Group 21: Hydraulic Brake System — Tests

Check the Braking Pressure

Section 270: Hydraulic System — Operation and Tests

Group 05: Safety

Recommendations

Group 10: General Information

Hydraulic Symbols (As Defined by ISO 1219)

Group 15: MaxiCut Precutter Hydraulic System — Description

Pickup Attachment and MAXICUT MAXICUT is a trademark of Deere & Company Precutter System

Description and Diagram

Group 16: MaxiCut Precutter Hydraulic System — Tests

MaxiCut Precutter Hydraulic System — Tests - Essential or Recommended Tools

MaxiCut Precutter Hydraulic System — Tests - Specifications

Check Pickup Lift Function

Check Gear Case Reverser Function

Check Knife Function

Check Solenoid Valve Function

Group 20: Main Control Valve — Description

Main Control Valve — Description — Summary of References

Group 20A: Main Control Valve — Description (S.N. —088999)

Description and Diagram of Main Control Valve (S.N. —088999)

Group 20B: Main Control Valve — Description (S.N. 089000—)

Description and Diagram of Main Valve Control

Group 25: Bale Density/Gate Control — Description

Bale Density/Gate Control — Description — Summary of References

Group 25A: Bale Density/Gate Control — Description (S.N. —088999)

Bale Density/Gate Control — Specifications

Description and Diagram of Bale Density/Gate Control (S.N. —088999)

Starting a Bale

During Baling (S.N. —088999)

Opening the Gate

Closing the Gate

Group 25B: Bale Density/Gate Control — Description (S.N. 089000—)

Bale Density/Gate Control — Description (S.N. 089000—) — Specifications

Description and Diagram of Bale Density Control Valve

Component Description

Start a Bale

During Baling

Open the Gate

Close the Gate

Group 26: Bale Density/Gate Control — Tests

Bale Density/Gate Control — Tests — Summary of References

Group 26A: Bale Density/Gate Control — Tests (S.N. —088999)

Essential Tools (S.N. —088999)

Specifications (S.N. —088999)

Check Bale Density Hydraulic System (S.N. —088999)

Check Gate Operation Hydraulic System (S.N. —088999)

Check Bale Density Gauge

Check Bale Density Adjustable Relief Valve and Check Valve

Check Valve Pilot Piston Check

Check Safety Relief Valve

Check Hydraulic Cylinder for Leakage

Check Gate Lock Valve for Leakage

Group 26B: Bale Density/Gate Control — Tests (S.N. 089000—)

Bale Density/Gate Control — Tests (S.N. 089000—) — Essential or Recommended Tools

Bale Density-Gate Control — Tests (S.N. 089000—) — Specifications

Check Bale Density Hydraulic System

Check Gate Operation Hydraulic System

Check Bale Density Gauge (S.N. 089000—)

Check Bale Density Adjustable Relief Valve and Check Valve (S.N. 089000—)

Check Gate Pilot-operated Valves

Check Hydraulic Cylinder for Leakage (S.N. 089000—)

Group 30: Wrapping System — Description

Wrapping System — Description — Summary of References

Group 30A: Wrapping System — Description (S.N. —088999)

Description and Diagram — Wrapping System Control

Group 30B: Wrapping System — Description (S.N. 089000—)

Description and Diagram of Wrapping System Control

Section 330A: Net Tying — Operation and Tests

Group 05: Troubleshooting

Standard Net Tying Device Difficulties

CoverEdge Net Tying Device Difficulties

Group 10: Theory of Operation

How the Net Tying Works

Section 330B: Twine Tying — Operation and Tests

Group 05: Troubleshooting

Troubleshooting

Section 399: Special Tools — Dealer-Fabricated

Group 05: Manufacturing the Tools

OMP Hydraulic Motor Seal Installer

OMS Hydraulic Motor Seal Installer

John Deere Hay and Forage Wrapping Balers Models 678 Diagnosis and Repair Service Manual (TM3301)