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)