Complete service repair manual for John Deere Combines Models W540, W550, W650, W660, T550, T560, T660, T670 with Wide Cab (International edition) (MY2012-MY2013) , with workshop information to maintain, repair, and service like professional mechanics.

John Deere Combines W540, W550, W650, W660, T550, T560, T660, T670 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.

TM404219 - John Deere Combines W540, W550, W650, W660, T550, T560, T660, T670 Technical Manual (Repair).PDF
TM404219 - John Deere Combines W540, W550, W650, W660, T550, T560, T660, T670 Technical Manual (Repair).EPUB

Total Pages: 2,513 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   General Information
      Safety
      Specifications
      General Repair Information
      Fuel, Lubricants, Coolant and Capacities
   Engine
      Remove and Install Engine
      Cooling System
   Fuel System and Air Intake System
      Air Intake System
      Diesel Fuel System
   Electrical System
      Harness and Connector Repair
      Batteries
      Wiring Harness Routing
      Power Distribution and Location of Control Units
      Switches, Sensors and Motors
      Electromagnetic Valves
      Lights
      Operator`s Station
      Windshield Wiper
      Alternator
      Starting Motor
      GreenStar™ Components
   Power Train
      Transmission and Differential - Three-Speed Transmission
      Hydrostatic System - Three-Speed Transmission
      Transmission and Differential - ProDrive™ Transmission
      Hydrostatic Drive Pump - ProDrive™ Transmission
      Hydrostatic Drive Motor - ProDrive™ Transmission
      Final Drives
      Cam Lobe Motor
      HillMaster™ System
   Steering and Brakes
      Steering System
      Brakes - Three-Speed Transmission
      Brakes - ProDrive™ Transmission
   Hydraulic System
      Hydraulic Oil Reservoir
      Hydraulic Pumps
      Hydraulic Valves
      Hydraulic Cylinders
      HillMaster™ II Hydraulic Cylinders
      Motor
      Accumulators
   Separator Shell
      Gull Wing Doors
   Operator`s Station
      Air Conditioning System (R134a)
      System Components
      Operator`s Cab
   Feeder House Repair
      Feeder House
      Upper Shaft and Slip Clutch
      Feeder House Drives and Reverser Gear Case
      HeaderTrak™ Tilt Cylinder and Frame
      HillMaster™ II Tilt Cylinder and Frame
   Separator, W-Series Combines
      Separator Repair
      Beater (T Series)
      Separator Rotor/Separator Grate (T Series)
      Separator Grate (T Series)
      Overshot Beater/Stripper (T Series)
      Cylinder Drives
      Walkers, Walker Shafts and Walker Return Pan
      Straw Chopper and Chaff Spreader
      Shoe Supply Augers, Cleaning Fan, Chaffer/Sieve Frame
      Tailings Elevator and Augers
      Tailings Elevator and Auger Slip Clutch (T Series)
      Primary Countershaft
      Header Electromagnetic Clutch
   Grain Tank and Unloading System
      Grain Tank Cross Augers
      Auger System Drives
      Vertical Auger and Lower Gear Case
      Horizontal Auger and Gear Case
      Clean Grain Elevator and Loading Auger Gear Case
      Grain Tank and Extensions
   Engine Gear Case and Control Valve
      Engine Gear Case and Valve
   Special Tools
      Essential Special Tools
      Recommended Special Tools

tm404219 - W540, W550, W650, W660, T550, T560, T660, T670 combines - MY2012, wide cab - repair -: (International edition)

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Follow Safety Instructions

Understand Signal Words

Prevent Battery Explosions

Handling Batteries Safely

Wait Before Opening High-Pressure Fuel System

Prepare for Emergencies

Handle Fluids Safely—Avoid Fires

Prevent Acid Burns

Avoid High-Pressure Fluids

Protect Against High Pressure Spray

Prevent Machine Runaway

Park Machine Safely

Live With Safety

Install All Guards

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Service Cooling System Safely

Stay Clear of Rotating Drivelines

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Service Tires Safely

Avoid Heating Near Pressurized Fluid Lines

Avoid Hot Exhaust

Remove Paint Before Welding or Heating

Use Proper Tools

Construct Dealer-Made Tools Safely

Practice Safe Maintenance

Protect Against Noise

Dispose of Waste Properly

Avoid Harmful Asbestos Dust

Use Adequate Service Facilities

Servicing Electronic Control Units

Welding Near Electronic Control Units

Precautions for Welding

Keep Electronic Control Unit Connectors Clean

Clean Exhaust Filter Safely

Handle Fuel Safely—Avoid Fires

Handle Starting Fluid Safely

Exhaust Filter Cleaning

Group 10: Specifications

Operating Speeds

Specifications - W540 and W550 Combines

Specifications - W650 and W660 Combines

Specifications - Combines T550 and T560

Specifications - T660 and T670 Combines

Dimension Reference Points (W Series)

Dimensions (W Series)

Dimension Reference Points (T Series)

Dimensions (T Series)

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Assemble and Install Flat Face Seal Fittings - All Pressure Applications

Torque Chart for Metric Flat Face Seal Fittings - Standard Pressure Applications

Torque Chart for Metric Flat Face Seal Fittings - High Pressure Applications

Torque Chart for SAE Flat Face Seal Fittings - Standard Pressure Applications

Torque Chart for SAE Flat Face Seal Fittings - High Pressure Applications

Assemble and Install Four-Bolt Flange Fittings - All Pressure Applications

Torque Values for SAE Four-Bolt Flange - Standard Pressure Applications

Torque Values for SAE Four-Bolt Flange - High Pressure Applications

Group 15: General Repair Information

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

Programming Control Units

Group 20: Fuel, Lubricants, Coolant and Capacities

Handle Fuel Safely—Avoid Fires

Handling and Storing Diesel Fuel

Lubricity of Diesel Fuel

Diesel Fuel

Testing Diesel Fuel

Biodiesel Fuel

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere Break-In™ Plus Engine Oil

Heavy Duty Diesel Engine Coolant

Supplemental Coolant Additives

Drain Intervals for Diesel Engine Coolant

Operating in Warm Temperature Climates

Testing Diesel Engine Coolant

Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER

John Deere COOL-GARD™ II Coolant Extender

Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender

Liquid Coolant Conditioner

Diesel Engine Oil

Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils

Transmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger Elevator and Dual-Range Cylinder Drive Gear Cases

Grease

Lubricant Storage

Mixing of Lubricants

Alternative and Synthetic Lubricants

Oilscan™ and CoolScan™

Capacities

Section 20: Engine

Group 05: Remove and Install Engine

Essential or Recommended Tools

Specifications

John Deere Engine Repair—Use CTM

Remove Engine—Non IT4

Install Engine—Non IT4

Remove Engine—9.0 L (Interim Tier 4/Stage III B)

Install Engine—9.0 L (Interim Tier 4/Stage III B)

Remove and Install Flywheel Pilot Bearing

Remove and Install Aftertreatment Device Assembly

Disassemble and Assemble Aftertreatment Device

Group 15: Cooling System

John Deere Engine Repair—Use CTM

Remove and Install Rotary Screen

Remove and Install Rotary Screen Drive

Rotary Screen Drive Exploded View (Interim Tier 4/Stage III B)

Remove and Install Rotary Screen Idler Arm and Sheaves

Rotary Screen Idler Arm and Sheaves Exploded View (Interim Tier 4/Stage III B)

Remove and Install Rotary Screen Brush Kit (Optional)

Rotary Screen Exploded View (Interim Tier 4/Stage III B)

Remove and Install Rotary Screen

Remove and Install Rotary Screen Door

Vacuum Fan Assembly Exploded View (Interim Tier 4/Stage III B)

Remove and Install Vacuum Fan Jackshaft

Remove and Install Vacuum Fan Assembly

Remove and Install Vacuum Fan Impeller

Remove Cooling Package (Interim Tier 4/Stage III B)

Install Cooling Package (Interim Tier 4/Stage III B)

Remove and Install Oil Cooler (Interim Tier 4/Stage III B)

Remove and Install Radiator

Remove Radiator (Interim Tier 4/Stage III B)

Install Radiator (Interim Tier 4/Stage III B)

Variable Speed Fan Drive and Driven Assembly Exploded View (Interim Tier 4/Stage III B)

Replace Variable Speed Fan Drive Belt (Interim Tier 4/Stage III B)

Remove and Install Variable Speed Fan Drive Assembly (Interim Tier 4/Stage III B)

Disassemble and Assemble Variable Speed Fan Drive Assembly (Interim Tier 4/Stage III B)

Remove and Install Variable Speed Fan Driven Assembly (Interim Tier 4/Stage III B)

Disassemble and Assemble Variable Speed Fan Driven Assembly (Interim Tier 4/Stage III B)

Lubricate Variable Speed Fan Drive and Driven Assemblies (Interim Tier 4/Stage III B)

Test Radiator

Test Radiator Cap

Replace Thermostats

Repair or Replace Water Pump

Section 30: Fuel System and Air Intake System

Group 05: Air Intake System

Specifications

John Deere Engine Repair—Use CTM

Remove and Install Turbocharger

Turbocharger Repair

Remove and Install Charge Air Cooler

Remove and Install Charge Air Cooler (Interim Tier 4/Stage III B)

Cleaning Charge Air Cooler

Group 10: Diesel Fuel System

Specifications

Remove and Install Fuel Tank

Remove and Install Fuel Tank Shutoff Valve

Replace Fuel Filter (6.8-Liter Engine)

Replace Water Separator Filter (6.8-Liter Engine)

Remove and Install Fuel Filters (9.0-Liter Engine)

Fuel Filters — Removal (Interim Tier 4/Stage III B)

Fuel Filters — Installation (Interim Tier 4/Stage III B)

Clean the Fuel Precleaner (9.0-Liter Engine)

Flush Fuel Precleaner (Heavy-Duty; Option)

Clean Fuel Precleaner (Heavy-Duty; Option)

Replace Fuel Precleaner (Heavy-Duty; Option)

Remove and Install Fuel Prefilter (Interim Tier 4/Stage III B)

Remove and Install Fuel Cooler (Interim Tier 4/Stage III B)

Section 40: Electrical System

Group 05: Harness and Connector Repair

Essential or Recommended Tools

Other Material

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 10: Batteries

Prevent Battery Explosions

Handling Batteries Safely

Avoid Damage to Electrical System

Checking Electrolyte Specific Gravity

Remove and Install Battery

Charging Batteries

Group 15: Wiring Harness Routing

Replace Harness

Cab Main Wiring Harness

Cab Main Wiring Harness

Cab Roof Wiring Harness

Location of Wiring Harnesses, L.H. Side of Machine

Location of Wiring Harnesses, R.H. Side of Machine

Group 20: Power Distribution and Location of Control Units

Fuse Identification

Diodes on 6.8 and 9.0 Liter Engines

Remove and Install HVAC Power Module

Remove and Install Cab Power Modules

Remove and Install R.h. and L.h. Power Module

Location of Control Units

Location of Control Units (Interim Tier 4/Stage III B)

Ground Points

Group 25: Switches, Sensors and Motors

Essential or Recommended Tools

Other Material

Location of Shaft Speed Sensors, L.H. Side of Machine

Location of Shaft Speed Sensors, R.H. Side of Machine

Remove And Install Low Shaft Speed Sensor

Remove and Install Full Grain Tank Sensor

Remove and Install Tailings Sensor

Remove and Install VisionTrak VisionTrak is a trademark of Deere & Company. Sensors (Shoe/Separator), B21, B22, B23 and B24

Remove and Install Concave Position Sensor, B17

Remove and Install Sensors for Header Height (B9) and Tilt (B20)

Remove and Install Back-Up Alarm Switch

Remove and Install Hillmaster Sensor, B70

Remove and Install Hydraulic Reservoir Temperature Sensor

Location of Sensors on ProDrive Transmission

Location of Switches on ProDrive Transmission

Location of Sensors on Push Button Shift Transmission

Location of Switches on Hydrostatic Pump— ProDrive Transmission

Remove and Install Park Brake Switch

Remove and Install Ground Speed Sensor

Remove and Install Hydro Charge Pressure Switch

Remove and Install Pressure Switch B55 of Header Control

Remove and Install Coolant Low Switches S55 and S57

Remove and Install Fuel Level Sensor B67

Remove and Install Air Filter Restriction Switch

Remove and Install Fuel Transfer Pump Pressure Sensor—9.0 L Engine

Remove and Install Engine Gear Case Temperature and Pressure Switches

Remove and Install Engine Oil Pressure Sensor

Remove and Install Compressor Inlet Temperature Sensor

Remove and Install Evaporator Temperature Sensor

Remove and Install Air Temperature Sensors

Remove and Install Pump Position Sensor—9.0 L Engine

Remove and Install Engine Speed Sensor

Remove and Install Water in Fuel Sensor

Remove and Install Variable Speed Fan Driven Sensor

Remove and Install Exhaust Gas Recirculation (EGR) Exhaust Gas Temperature and Fresh Air Temperature Sensors

Remove and Install Intake Manifold Pressure and Exhaust Gas Recirculation (EGR) Mixed Gas Temperature Sensor

Remove and Install Turbocharger Speed Sensor

Remove and Install Fuel Temperature Sensor

Remove and Install Fuel Rail Pressure Sensor—9.0 L Engine

Remove and Install Multi-Function Lever Feed Rate Sensor

Remove and Install Steering Input Device Sensor

Remove and Install Switches for Shoe Adjustment, Shoe Lights and Service Lights

Remove and Install Chaffer and Sieve Adjusting Motors

Remove and Install Miscellaneous Motors

Remove and Install Wheel Angle Sensor

Remove and Install Particulate Filter Sensors

Group 30: Electromagnetic Valves

Electromagnetic Valves on Main Valve Block

Electromagnetic Valves on Header Height Control Valve Block

Electromagnetic Valves on Feeder House

Electromagnetic Valves in Engine Compartment

Electromagnetic Valve on Three Speed Transmission

Electromagnetic Valves on ProDrive Transmission

Electromagnetic Valves on Push Button Shift Transmission

Four-Wheel Drive Electromagnetic Valves

Electromagnetic Valves on Engine Fan Clutch

Group 35: Lights

Safety Rules When Replacing Halogen Bulbs

Safety Rules When Replacing High Intensity Discharge (HID) Xenon Bulbs

Cab Halogen Round Headlight Bulb Replacement and Adjustment

Cab Halogen Oval Light Bulb Replacement and Adjustment

High Intensity Discharge (HID-Xenon) Light Replacement and Adjustment

Remove and Install High Intensity Discharge (HID-Xenon) Ballasts (If Equipped)

Header Flood Light Bulb Replacement (If Equipped)

Low Beam Driving Light Bulb Replacement and Adjustment (If Equipped)

Remove and Install Header Flood Light Housing (If Equipped)

Remove and Install Low Beam Driving Light Housing (If Equipped)

Rotary Beacon Bulb Replacement

Auxiliary Field, Access Door, Grain Tank, Unload Auger and Work Light Bulb Replacement

Side Finder (Optional) Light Bulb Replacement

Hazard/Warning Light Bulb Replacement

Dome Light Bulb Replacement

Group 40: Operator's Station

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

Remove and Install Modular Telematics Gateway 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 Control Lever Position Switches

Remove and Install Ignition Switch

Remove and Install Starting Aid 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 Hands Free Microphone

Remove and Install Map Light Assembly

Group 45: Windshield Wiper

Specifications

Remove and Install Windshield Wiper Arms

Remove and Install Windshield Wiper Motor

Remove and Install Windshield Washer

Adjust Windshield Wiper Arms

Group 50: Alternator

Essential or Recommended Tools

Specifications

John Deere Engine Accessories—Alternator Repair

Remove and Install Alternator and Alternator Belt

Remove and Install Alternator and Alternator Belt (Interim Tier 4/Stage III B)

Remove and Install Alternator Pulley

Group 55: Starting Motor

Essential or Recommended Tools

Specifications

John Deere Starting Motor Repair

Remove and Install Starting Motor

Remove and Install Starting Motor (Interim Tier 4/Stage III B)

Group 60: GreenStar™ Components

Specifications

Other Material

Remove and Install GreenStar Mass-Flow Sensor

Remove and Install GreenStar Moisture Sensor

Disassemble and Assemble GreenStar Moisture Sensor

Remove and Install GreenStar Moisture Sensor Actuator

Remove and Install GreenStar Moisture Sensor Circuit Board

Remove and Replace GreenStar Moisture Sensor Lower Cell Assembly

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

Other Material

Specifications

Remove Transmission

Remove and Repair Shifter Forks and Shifter Cam

Install Shifter Forks and Shifter Cam

Remove and Install Transmission Lube Pump

Remove and Install Suction Screen

Transmission Components

Disassemble and Repair Transmission

Assemble Transmission

Install Transmission

Remove and Install Gearshift Lever and Linkage

Adjust Gearshift Linkage

Remove Transmission (PBST)

Remove and Repair Shifter Forks (PBST)

Install Shifter Forks (PBST)

Remove and Install Transmission Lube Pump (PBST)

Push Button Shift Transmission (PBST) Exploded View

Disassemble and Repair Transmission (PBST)

Assemble Transmission (PBST)

Remove and Install Park Brake Actuator (PBST)

Disassemble and Assemble Park Brake Actuator (PBST)

Valve Block Shifter (PBST) Exploded View

Install Transmission (PBST)

Group 10: Hydrostatic System - Three-Speed Transmission

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Serial Number Plate

Clean Hydrostatic Motor and Pump

Flushing the Hydrostatic System

Remove and Install Hydrostatic Motor

Disassemble Hydrostatic Motor

Inspect Parts

Lack of Lubrication

Abrasive Contamination

Cavitation

Over Speeding

Inspect Thrust Plate

Inspect Fixed Swashplate

Inspect Piston Slipper

Inspect Piston Retainer

Inspect Cylinder Block

Inspect Bearing Plate

Inspect Valve Plate

Inspect Bearing and Race

Inspect Servo Piston

Inspect Drive Shaft

Replace Cylinder Block Spring

Assemble Motor

Remove and Install Motor Valve Block (Manifold)

Repair Motor Valve Block

Remove and Install Hydrostatic Pump

Disassemble Drive Pump

Assemble Drive Pump

Replace High-Pressure Line Center Pivot O-Rings

Disassemble and Assemble End Cover

Repair Displacement Control Valve

Displacement Control Valve with Feed Rate - Exploded View

Disassemble and Assemble DisplacementControl Valve with Feed Rate (Optional)

Electronic Proportional Displacement Control Valve Neutral Adjustment

Install Hydrostatic Pump

Remove and Install Charge Pump

Repair Charge Pump

Remove and Install Hydrostatic Control Cable

Adjust Hydrostatic Control Linkage

Adjust Neutral Position of Displacement Control Valve

Start-Up Procedure After Hydrostatic System Repair

Group 15: Transmission and Differential - ProDrive™ Transmission

Service Equipment and Tools

Other Material

Specifications

Drain Oil

Remove Transmission

Transmission Components—Overview

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 (Forward/Reverse)

Disassemble and Assemble Gear-Shift Planetary Drive With Clutch (Forward/Reverse)

Install Gear-Shift Planetary Drive With Clutch (Forward/Reverse)

Remove and Install Countershaft

Repair Countershaft

Countershaft—Exploded View

Remove and Install Filter Screen

Replace Proportionator Pump Bushing

Remove and Install Proportionator Motor

Proportionator Motor Exploded View

Disassemble and Assemble Proportionator Motor

Assemble Transmission

Install Transmission

Group 20: Hydrostatic Drive Pump - ProDrive™ Transmission

Service Equipment and Tools

Recommended Special Tools

Specifications

General View

Serial Number Plate

Clean Variable Pump

Remove and Install Hydrostatic Pump

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

Assemble Pump

Install Rotary Group

Adjust Zero Position

Group 25: Hydrostatic Drive Motor - ProDrive™ Transmission

Service Equipment and Tools

Specifications

Identification of Axial Piston Machine

Remove and Install Hydrostatic Drive Motor

General View

Replace Cover Plate Seal

Replace Cover Plate Seal

Replace Port Plate Control Seals

Remove and Install Port Plate Control Rod

Disassemble and Assemble Flushing Valve

Disassemble Port Plate

Assemble Port Plate

Disassemble Rotary Group

Inspection Notes

Assemble Rotary Group

Adjust Rotary Group

Group 30: Final Drives

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive

Disassemble and Assemble Final Drive

Adjust Spindle Bearing (Preferred Method)

Adjust Spindle Bearing (Alternate Method)

Group 35: Cam Lobe Motor

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Flush Cam Lobe Motors

Remove Cam Lobe Motor

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 Valve Block Seals

Remove and Install Axle Bearings and Seals

Group 40: HillMaster™ System

HillMaster II Rocker Assembly - Right

HillMaster II Rocker Assembly - Left

Section 60: Steering and Brakes

Group 05: Steering System

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove Steering Valve

Steering Valve—Without AutoTrac Option

Disassemble Steering Valve—Without AutoTrac Option

Assemble Steering Valve—Without AutoTrac Option

Disassemble Steering Valve—With AutoTrac Option

Electrohydraulic Steering Valve—With AutoTrac Option

Assemble Steering Valve—With AutoTrac Option

Install Steering Valve

Steering Column-Exploded View

Disassemble and Assemble Steering Column

Replace Telescoping Shaft Bearings

Remove and Install Steering Cylinder

Repair Steering Cylinder

Adjust Toe-In

Remove and Install Steering Tie Rod

Remove and Install Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive

Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive

Remove and Install Rear Axle Pivot Bushing

Rear Axle Adjustment

Group 10: Brakes - Three-Speed Transmission

Service Equipment and Tools

Other Material

Specifications

Deglazing Brake Linings

Park Brake Release (PBST)

Remove and Install Brake Drum (PBST)

Remove Brake Shoe (PBST)

Remove Brake Drum

Remove Brake Shoes - Heavy Duty Version

Recondition Brakes - Heavy Duty Version

Assemble Brakes (PBST)

Assemble Brakes - Heavy Duty Version

Install Brake Drum

Remove and Install Master Cylinder

Disassemble and Assemble Master Cylinder (Double Bleed Screw)

Adjust Master Cylinder

Bleed Brake System (Double Bleed Screw)

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 - ProDrive™ Transmission

Service Equipment and Tools

Other Material

Specifications

Bleed Service Brakes

Disassemble and Assemble Brake Pedals

Disassemble and Assemble Oil Pressure Regulating Valve (Service Brake Circuit)

Repair Brake Disks

Remove and Install Accumulator

Section 70: Hydraulic System

Group 05: Hydraulic Oil Reservoir

Service Equipment and Tools

Specifications

Remove and Install Reservoir

Remove and Install Reservoir (Interim Tier 4/Stage III B)

Flushing the Hydraulic System

Flushing the Reel/Belt Pickup Drive System

Start-Up Procedure After Hydrostatic System Repair

Group 10: Hydraulic Pumps

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove Main Hydraulic Pump

Marking Hydraulic Pump

Disassemble Hydraulic Pump

Replace Seal

Triple Main Hydraulic Pump—Exploded View (Three Speed Transmission)

Quad Main Hydraulic Pump—Exploded View (ProDrive Transmission)

Assemble Triple Main Hydraulic Pump—Three Speed Transmission

Assemble Quad Main Hydraulic Pump—ProDrive Transmission

Install Main Hydraulic Pump

Remove Proportionator Pump—ProDrive Transmission

Proportionator Pump Exploded View

Assemble Proportionator Pump

Install Proportionator Pump—ProDrive Transmission

Reel/Belt Pickup Pump

Remove Chaff Spreader Pump

Disassemble Chaff Spreader Pump

Chaff Spreader Pump

Assemble Chaff Spreader Pump

Install Chaff Spreader Pump

Remove Spreader Pump

Install Spreader 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

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Hydraulic Valve Block

Remove and Install Header Height Control Valve Block

Disassemble and Assemble Hydraulic Valve Stack

Disassemble and Assemble PBST Transmission Shift Valve

Remove and Install ProDrive Transmission Control Valve

Remove and Repair Valves From ProDrive Transmission Control Valve

ProDrive Transmission Control Valve Exploded View

Install Valves In ProDrive Transmission Control Valve

Remove and Install Hydraulic Service Brake Valve—ProDrive Transmission

Disassemble and Assemble Hydraulic Service Brake Valve—ProDrive Transmission

Adjust Hydraulic Service Brake Valve—ProDrive Transmission

Remove and Install Variable Speed Fan Drive Valve Block

Disassemble and Assemble Variable Speed Fan Drive Valve Block

Electro-Hydraulic Feeder House Reverser Valve - General Information

Disassemble Electro-Hydraulic Feeder House Reverser Valve

Remove Reel/Belt Speed Flow Control Valve

Repair Reel/Belt Speed Flow Control Valve

Install Reel/Belt Speed Flow Control Valve

Reel Reversing Control Valve

Remove and Install Reel Reversing Control Valve

Feeder House Multi-Coupler Check Valves - General View

Disassemble, Inspect and Assemble Feeder House Multi-Coupler

Remove Reverser Shift Valve Block

Remove and Install Header Height Control Valve Block

Disassemble and Assemble Header Height Control Valve Block

Group 20: Hydraulic Cylinders

Specifications

Remove and Install Header Lift Cylinder

Disassemble and Assemble Header Lift Cylinder

Remove and Install Unloading Auger Swing Cylinder

Adjust Unloading Auger Swing Cylinder

Remove and Install Unloading Auger Drive Cylinder

Adjust Unloading Auger Drive Cylinder

Group 21: HillMaster™ II Hydraulic Cylinders

Special Tool (Dealer-Fabricated)

Other Material

Specifications

General Information

Components of HillMaster II Cylinder

Check Valve Components

Components of Compensating Valve

Compensating Valve Installed in Piston

Attachment of HillMaster II Cylinders

Group 25: Motor

Remove and Install Chaff Spreader Motor

Group 30: Accumulators

Service Equipment and Tools

Accumulator (General Information)

Check Header Float System Accumulator

Accumulator Charge Pressure

Section 80: Separator Shell

Group 05: Gull Wing Doors

Other Material

Remove and Install Gull Wing Doors

Composite Panel Repair

Section 90: Operator's Station

Group 05: Air Conditioning System (R134a)

Essential or Recommended Tools

Air-Conditioning Service Unit

Service Equipment and Tools

Other Material

Specifications

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Discharge and Recovery of Air Conditioning Refrigerant

Remove and Install Compressor—6.8 L Engine

Remove and Install Compressor

Remove and Install Compressor—9.0 L Engine (Interim Tier 4/Stage III B)

Test Volumetric Efficiency

Leak Testing Air Conditioning System With Dye

Test Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Disassemble, Inspect, and Assemble Compressor

Remove and Install Compressor Relief Valve

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

Essential or Recommended Tools

Other Material

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 Condenser

Remove Condenser (Interim Tier 4/Stage III B)

Repair Condenser

Install Condenser

Install Condenser (Interim Tier 4/Stage III B)

Remove and Install Evaporator

Replace Expansion Valve

Remove and Install Evaporator Temperature Sensor

Replace Air Conditioning High/Low Pressure Switch

Replace Air Temperature Sensors

Group 15: Operator's 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 Operator Air Seat Suspension

Remove and Install Armrest Control Pivot

Remove and Install Operator Presence Switch

Operator Seat Exploded View

Disassemble and Assemble Operator Seat Air Suspension Assembly

Remove and Install Refrigerator

Remove and Install Cab Door

Disassemble and Assemble Cab Door Exploded View

Cab Door Latch Striker

Section 110: Feeder House Repair

Group 05: Feeder House

Other Material

Specifications

Remove and Install Feeder House

Remove and Install Conveyor Chain

Measure Conveyor Chain Wear

Remove Conveyor Chain Link

Replace Conveyor Chain Slats

Replace Conveyor Chain Wear Strips

Adjust Drum Height

Remove and Install Conveyor Drum

Conveyor Drum Exploded View - HillMaster II

Conveyor Drum Exploded View - Standard Combines and HeaderTrak Tilt

Remove And Install Mid-Floor Assembly

Remove And Install Sub-Floor Assembly

Remove and Install Pea Kit Sub-Floor Assembly (Optional)

Feed Plate Support - Exploded View

Group 10: Upper Shaft and Slip Clutch

Specifications

Remove and Install Top Shaft Supports

Disassemble and Assemble Conveyor Top Shaft

Group 15: Feeder House Drives and Reverser Gear Case

Other Material

Specifications

Top Shaft Idler - Exploded View

Feeder House Countershaft and Tensioner - Exploded View

Remove and Install Reverser Gear Case

Feeder House Reverser Gear Case - Exploded View

Disassemble and Assemble Feeder House Reverser Gear Case

Remove and Install Reverser Shift Piston

Remove and Install Lower Shaft

Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides

Group 20: HeaderTrak™ Tilt Cylinder and Frame

Specifications

HeaderTrak Tilt Cylinder Hoses and Fittings - Exploded View

Remove and Install HeaderTrak Tilt Cylinder

Feeder House Shell, Wear Plates and Seals, Location

Tilt Beam and Closure Plates,Location

Remove and Install Tilt Frame

Remove and Install Tilt Beam

Adjust Fore-Aft Turnbuckles

Remove Fore-Aft Tilt Frame

Install Fore-Aft Tilt Frame

Group 25: HillMaster™ II Tilt Cylinder and Frame

Specifications

Tilt Frame - Exploded View

Section 120: Separator, W-Series Combines

Group 05: Separator Repair

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Rasp Bars

Static Balance Cylinder

Remove Threshing Cylinder

Install Threshing Cylinder

Remove Concave

Install Concave

Level Concave (Rasp Bar)

Level Concave (Spike Tooth)

Concave Position Sensor and Linkage

Remove and Install Concave Adjusting Motor

Beater, Exploded View

Disassemble and Assemble Beater

Remove and Install Beater

Group 06: Beater (T Series)

Specifications

Other Material

Remove and Install Beater

Remove Speed Sensor (Left Side)

Remove Locking Collar

Remove Beater Pulley (Right Side)

Remove Hub and Speed Sensor (Right Side)

Remove Beater Grate

Disassemble Beater

Install Beater Grate

Remove Bearing

Remove Shaft

Install Beater

Group 07: Separator Rotor/Separator Grate (T Series)

Specifications

Remove and Install Separator Rotor

Measure Distance from Pulley to Sidewall

Remove Pulley (Left Side)

Remove Pulley (Right Side)

Remove Hub

Remove Finger Bars and Retaining Plates

Loosen Segment Clamping Screws

Remove Bearings

Install Separator Rotor

Group 08: Separator Grate (T Series)

Specifications

Remove and Install Separator Grate

Remove Finger Bars of Separator Rotor

Remove Separator Grate Inserts

Position Separator Grate

Lift Out Separator Grate

Install and Adjust Separator Grate

Group 09: Overshot Beater/Stripper (T Series)

Specifications

Remove and Install Overshot Beater

Remove Pulley

Remove Gearcase

Disassemble Overshot Beater

Remove Locking Collar (Right Side)

Install Overshot Beater

Remove and Install Stripper

Remove Pulley

Remove Locking Collar (Right Side)

Remove stripper from the front

Stripper Roll, Exploded View

Install Stripper

Group 10: Cylinder Drives

Essential or Recommended Tools

Other Material

Specifications

Remove Cylinder Drive Sheave

Install Cylinder Drive Sheave

Remove Dual Range Cylinder Drive Gear Case

Install Dual Range Cylinder Drive Gear Case

Dual Range Cylinder Drive, Exploded View

Disassemble and Assemble Dual Range Cylinder Drive Gear Case

Remove and Install Intermediate Cylinder Drive

Repair Intermediate Cylinder Drive

Remove and Install Intermediate Cylinder Drive Support

Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave

Group 15: Walkers, Walker Shafts and Walker Return Pan

Essential or Recommended Tools

Other Material

Specifications

All Walkers - Timing Procedure

Remove and Install Straw Walker Bearings and Walker Return Pan

Remove and Install Rear Walker Shaft

Remove and Install Front Walker Shaft

Remove and Install Straw Walker Gear Case (W Series)

Remove Straw Walker Drive (T Series)

Disassemble and Assemble Straw Walker Gearcase

Remove and Install Power Separator

Group 20: Straw Chopper and Chaff Spreader

Service Equipment and Tools

Other Material

Specifications

Chopper Rotor

Chopper Housing and Knife Bank

Remove Straw Chopper

Replace Chopper Blades

Replace Knife Sections

Remove and Install Rotor Bearings

Remove and Install Straw Chopper Jackshaft

Disassemble and Assemble Straw Chopper Jackshaft

Remove and Install Straw Chopper Idler Assembly

Group 25: Shoe Supply Augers, Cleaning Fan, Chaffer/Sieve Frame

Other Material

Specifications

Replace Shoe Supply Augers

Replace Shoe Supply Auger Wooden Bearings

Remove and Install Shoe Supply Auger Drive Shaft

Remove and Install Shoe Supply Auger Trough

Remove Separator Drive Jackshaft

Install Separator Drive Jackshaft

Remove and Install Cleaning Fan Drive

Fan Drive Speed Control

Remove Cleaning Fan

Install Cleaning Fan

Remove and Install Cleaning Fan Housing

Adjust Fan Speed Actuator

Remove Chaffer, Sieve and Frames

Install Chaffer, Sieve and Frames

Remove and Install Shoe Pitman Arms

Group 30: Tailings Elevator and Augers

Disassemble Tailings Elevator and Augers

Group 31: Tailings Elevator and Auger Slip Clutch (T Series)

Park Machine Safely

Remove Slip Clutch for Tailings Elevator and Auger

Disassemble Slip Clutch

Install Brass Disk and Assemble Slip Clutch

Install Slip Clutch and Tension Drive Belts

Group 35: Primary Countershaft

Essential or Recommended Tools

Specifications

Remove and Install Primary Countershaft Gear Case

Disassemble and Assemble Primary Countershaft Gear Case

Remove and Install Primary Countershaft with Variable Sheave Assembly

Remove and Install Beater Curtain

Group 40: Header Electromagnetic Clutch

Specifications

Remove Header Electromagnetic Clutch

Disassemble and Assemble Header Electromagnetic Clutch

Install Header Electromagnetic Clutch

Section 130: Grain Tank and Unloading System

Group 05: Grain Tank Cross Augers

Remove and Install Grain Tank Cross Augers

Group 10: Auger System Drives

Specifications

Replace Unloading Auger Drive Belts

Remove and Install Cross Auger Countershaft Hub and Shear Bolt

Remove Unloading Auger Drive Countershaft

Install Unloading Auger Drive Countershaft

Align Unloading Auger Drive

Adjust Unloading Auger Drive Cylinder

Replace Unloading Auger Grain Saver Door

Group 15: Vertical Auger and Lower Gear Case

Essential or Recommended Tools

Specifications

Remove Vertical Auger Lower Gear Case And Vertical Auger

Disassemble and Assemble Vertical Auger Lower Gear Case

Install Vertical Auger and Vertical Auger Lower Gear Case

Group 20: Horizontal Auger and Gear Case

Essential or Recommended Tools

Other Material

Specifications

Inspection of Horizontal Unloading Auger

17 ft. (5.18 m) and 20 ft. (6.1 m) Augers - Two-Piece

Remove Horizontal Auger

Install Horizontal Auger

Remove Horizontal Auger Gear Case

Disassemble And Assemble Horizontal Unloading Auger Gear Case

Install Horizontal Auger Gear Case

Remove Horizontal Unloading Auger Tube

Unloading Auger Elbow, Exploded View

Remove Horizontal Unloading Auger Elbow

Install Horizontal Unloading Auger Elbow

Remove Unloading Auger Charge Housing

Group 25: Clean Grain Elevator and Loading Auger Gear Case

Other Material

Specifications

Adjust Clean Grain Elevator Chain

Replace Clean Grain Elevator Belt

Clean Grain Loading Auger, Exploded View

Replace Clean Grain Loading Auger Bearing

Remove Clean Grain Loading Auger Assembly

Remove and Install Clean Grain Elevator Gear Case

Disassemble and Assemble Clean Grain Elevator Gear Case

Remove Clean Grain Elevator

Group 30: Grain Tank and Extensions

Grain Tank Base

Grain Tank

Grain Tank Covers - 8,000 and 9,000 Liters

Grain Tank Cover Seals - 8,000 and 9,000 Liters

Grain Tank Cover Supports - 8,000 and 9,000 Liters

Grain Tank Cover Cylinders - 8,000 and 9,000 Liters

Grain Tank Cover Actuator - 8,000 and 9,000 Liters

Grain Tank, General View - 11,000 Liters

Grain Tank Covers - 11,000 Liters

Grain Tank Lift Cylinders and Linkage - 11,000 Liters

Section 140: Engine Gear Case and Control Valve

Group 05: Engine Gear Case and Valve

Essential or Recommended Tools

Other Material

Specifications

General Information

Remove and Install Engine Gear Case

Engine Gear Case Specifications

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

Disassemble and Assemble Dipstick Tube

Remove and Install Filter

Remove and Install Pressure Regulating Valve

Disassemble and Assemble Pressure Regulating Valve

Section 199: Special Tools

Group 05: Essential Special Tools

Tools (Section 20)

Tools (Section 40)

Tools (Section 50)

Tools (Section 60)

Tools (Section 70)

Tools (Section 90)

Tools (Section 120)

Tools (Section 130)

Tools (Section 140)

Group 10: Recommended Special Tools

DFRW20—Compressor Holding Fixture

Adapter for Straw Walker Crankshaft

Cooling Fin Straightener

Special Tool for Disassembling Valve Seat and Piston

Special Tool for Positioning Swash Plate

John Deere Combines W540, W550, W650, W660, T550, T560, T660, T670 Service Repair Manual (TM404219)