John Deere S540 S550 S660 S670 S680 S690 Combine Workshop Repair Service Manual PDF (TM803819) - MJODTM803819.zip
A complete factory-style service and repair guide for John Deere S540, S550, S660, S670, S680, and S690 Combines, packed with every technical detail needed to service, fix, and rebuild these machines the way professional technicians do.
The John Deere Combines S540, S550, S660, S670, S680, S690 workshop service repair manual contains:
* 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