S540, S550, S660, S670, S680 and S690 Combines Diagnostic (SN. 120100—)
DIAGNOSTIC TECHNICAL MANUAL S540, S550, S660, S670, S680 and S690 Combines (SN. 120100—) TM805419 01DEC18 (ENGLISH)
For complette service information also see: S650 STS, S660 STS, S670 STS, S680 STS S685 STS & S690 STS Combine Repair (Worldwide Edition) .................. tm120819
John Deere Horizontina
Introduction Foreword
Operation and tests sections help you identify the majority of routine failures quickly.
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
TM805419 (01.12.2018)
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. DX,TMIFC-19-20140415
S540, S550, S660, S670, S680 and S690 Combines
Contents Section 210 - General Group 05 - Safety Group 10 - Combine and Component Identification Group 15 - General Specifications Group 20 - Diagnostic and Testing Procedures
Section 211 - Diagnostic Trouble Codes Group 1 - Accessing Diagnostic Codes and Addresses Group 2 - ATC - Diagnostic Trouble Codes Group 3 - AYM - Diagnostic Trouble Codes Group 4 - CAB - Diagnostic Trouble Codes Group 5 - CRU - Diagnostic Trouble Codes Group 6 - CSM - Diagnostic Trouble Codes Group 7 - ECU - Tier 2 and Tier 3 Engines - Diagnostic Trouble Codes Group 8 - EIC - Diagnostic Trouble Codes Group 10 - GLM - Diagnostic Trouble Codes Group 11 - JDL - Diagnostic Trouble Codes Group 12 - LC1 - Diagnostic Trouble Codes Group 13 - LC2 - Diagnostic Trouble Codes Group 14 - MHC - Diagnostic Trouble Codes Group 15 - PDU - Diagnostic Trouble Codes Group 16 - PTP - Diagnostic Trouble Codes Group 17 - RC1 - Diagnostic Trouble Codes Group 18 - RC2 - Diagnostic Trouble Codes Group 19 - SCL - Diagnostic Trouble Codes Group 20 - SFC - Diagnostic Trouble Codes Group 21 - SSU - Diagnostic Trouble Codes Group 22 - VTi - Diagnostic Trouble Codes Group 23 - XMC - Diagnostic Trouble Codes Group 24 - XSC - Diagnostic Trouble Codes
Section 212 - Observable Symptoms Group 230 - Air Intake and Cooling Systems Group 240 - Electrical System Group 245 - Electronic Control Units Group 250A - Drives - (S540, S550, S660, S670) Group 250B - Drives - (S680) Group 260A - Steering and Brakes - (S540, S550, S660, S670) Group 260B - Steering and Brakes - (S680) Group 270A - Hydraulic System - (S540, S550, S660, S670) Group 270B - Hydraulic System - (S680) Group 280A - Main Gearcase - (S540, S550, S660, S670) Group 280B - Main Gearcase - (S680) Group 290 - Cab/Open Operator Station
Section 220 - Engine System Group 20 - Engine Systems
Section 230 - Air Intake and Cooling System Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics
Section 239 - Air Intake and Cooling System - Components Section 240 - Electrical System Group 5A - General Information Group 10A - General References Group 10B - Calibration Procedures TM805419 (01.12.2018)
Group 20A - Theory of Operation - Cab/Operator`s Station Group 20C - Theory of Operation - Ag Management Solutions Group 20D - Theory of Operation - Lighting Group 20E - Theory of Operation - Engine/Fuel Group 20F - Theory of Operation - Starting/Charging/ Power Distribution Group 20G - Theory of Operation - Header Functions Group 20H - Theory of Operation - Feeder House Group 20I - Theory of Operation - Threshing/ Separating/Cleaning Group 20J - Theory of Operation - Grain Tank/ Unloading Group 20K - Theory of Operation - Residue System Group 20L - Theory of Operation - Transmission/ Ground Drive Systems Group 20M - Theory of Operation - Hydraulic Oil/ Pressure Group 20N - Theory of Operation - Main Gearcase Group 20O - Theory of Operation - Brakes Group 20P - Theory of Operation - Chassis Group 20Q - Theory of Operation - Air Compressor System Group 30A - Schematics - Cab/Operators Station Group 30C - Schematics - Ag Management Solutions Group 30D - Schematics - Lighting Group 30E - Schematics - Engine/Fuel Group 30F - Schematics - Starting/Charging/Power Distribution Group 30G - Schematics - Header Functions Group 30H - Schematics - Feeder House Group 30I - Schematics - Threshing/Separating/ Cleaning Group 30J - Schematics - Grain Tank/Unloading Group 30K - Schematics - Residue System Group 30L - Schematics - Transmission/Ground Drive Systems Group 30M - Schematics - Hydraulic Oil/Pressure Group 30N - Schematics - Main Gearcase Group 30O - Schematics - Brakes Group 30P - Schematics - Chassis Group 30Q - Schematics - Air Compressor System Group 50A - Diagnostics - Cab/Operator`s Station Group 50C - Diagnostics - Ag Management Solutions Group 50D - Diagnostics - Lighting Group 50E - Diagnostics - Engine/Fuel Group 50F - Diagnostics - Starting/Charging/Power Distribution Group 50G - Diagnostics - Header Functions Group 50H - Diagnostics - Feeder House Group 50I - Diagnostics - Threshing/Separating/ Cleaning Group 50J - Diagnostics - Grain Tank/Unloading Group 50K - Diagnostics - Residue System Group 50L - Diagnostics - Transmission/Ground Drive Systems Group 50M - Diagnostics - Hydraulic Oil/Pressure Group 50N - Diagnostics - Main Gearcase Group 50O - Diagnostics - Brakes Group 50P - Diagnostics - Chassis S540, S550, S660, S670, S680 and S690 Combines
Group 50Q - Diagnostics - Air Compressor System
Section 245 - Electronic Control Units Group 05 - Electronic Control Units - Summary of References Group 10A - Accessing Diagnostic Trouble Codes and Addresses Group 10B - Diagnostic Addresses by Control Unit Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics
Section 249 Components
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Electrical
Connector
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Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics
Section 269 - Steering and Brakes Components Section 270A - Hydraulic System - (S540, S550, S660 and S670) Section 270B - Hydraulic System - (S680 and S690)
Section 250A - Drives - (S540, S550, S660 and S670)
Section 279 Components
Section 250B - Drives - (S680 and S690)
Section 280A - Main Gearcase - (S540, S550, S660 and S670)
Section 259 - Drives - Components Section 260A - Steering and Brakes - (S540, S550, S660, S670) Group 10A - Preliminary & Operational Checks Group 10D - Hydraulic Specifications Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics
Section 260B - Steering and Brakes - (S680 ad S690)
TM805419 (01.12.2018)
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Hydraulic
System
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Section 280B - Main Gearcase - (S680 and S690) Section 289 - Main Gearcase - Components Section 290 - Cab-Open Operator`s Station Section 299 - Cab-Operator`s Station Components
S540, S550, S660, S670, S680 and S690 Combines
Section 210
General Contents Page
Page
Interpreting Engine Serial Number ....................... . 210-10-3
Group 05 - Safety Recognize Safety Information .............................. . 210-05-1 Handle Fluids Safely-Avoid Fires .......................... 210-05-1 Prepare for Emergencies...................................... . 210-05-1 Prevent Battery Explosions .................................. . 210-05-2 Prevent Acid Burns............................................... . 210-05-2 Handle Chemical Products Safely ......................... 210-05-2 Handle Starting Fluid Safely ................................. . 210-05-3 Avoid High-Pressure Fluids .................................. . 210-05-3 Park Machine Safely............................................. . 210-05-3 Support Machine Properly .................................... . 210-05-4 Wear Protective Clothing ...................................... . 210-05-4 Protect Against Noise ........................................... . 210-05-4 Work in Clean Area .............................................. . 210-05-4 Work In Ventilated Area ........................................ . 210-05-5 Illuminate Work Area Safely ................................. . 210-05-5 Service Machines Safely ...................................... . 210-05-5
Engine Serial Number .......................................... . 210-10-3 Hydrostatic Drive Unit Pump ................................ . 210-10-4 Hydrostatic Drive Unit Motor ................................ . 210-10-4 Two Speed Four-Wheel Drive Motor .................... . 210-10-5 Engine Gearcase.................................................. . 210-10-5 Rotor Drive Gearcase........................................... . 210-10-5 Transmission ........................................................ . 210-10-5 Feeder House Reverser ....................................... . 210-10-6 Multi-Speed Feeder House Gearcase (If 210-10-6 Equipped)...................................................... . Chopper (If Equipped) .......................................... . 210-10-6 Chopper Tailboard (Deluxe Residue) ................... . 210-10-6 PowerCast Tailboard (Deluxe Residue) ............... . 210-10-7 Spreader (Deluxe Residue).................................. . 210-10-7 Hydraulic Designators .......................................... . 210-10-7 Hydraulic Circuit Symbols .................................... . 210-10-8
Construct Dealer-Made Tools Safely ..................... 210-05-5
Group 15 - General Specifications
Service Cooling System Safely ............................ . 210-05-6
CARB Non-road Emissions Control Warranty 210-15-2 Statement-Compression Ignition................... .
Service Accumulator Systems Safely.................... 210-05-6 Wait
Before Opening High-Pressure Fuel 210-05-6 System .......................................................... .
Replace Safety Signs ........................................... . 210-05-6 Use Proper Lifting Equipment............................... . 210-05-7 Remove Paint Before Welding or Heating ............. 210-05-7 Avoid Heating Near Pressurized Fluid Lines ......... 210-05-7 Service Tires Safely.............................................. . 210-05-8 Avoid Harmful Asbestos Dust ............................... . 210-05-8 Practice Safe Maintenance................................... . 210-05-9 Use Proper Tools .................................................. . 210-05-9 Decommissioning - Proper Recycling and Disposal 210-05-9 of Fluids and Components ............................ . Live With Safety.................................................... . 210-05-10
EPA
Non-road Emissions Control Warranty 210-15-8 Statement-Compression Ignition................... .
Engine .................................................................. . 210-15-9 Electrical System.................................................. . 210-15-10 Transmission and Brakes ..................................... . 210-15-11 Feeding ................................................................ . 210-15-12 Separator.............................................................. . 210-15-13 Discharge ............................................................. . 210-15-14 Elevators and Cleaning Fan ................................. . 210-15-15 Unloading ............................................................. . 210-15-16 Turning Radius ..................................................... . 210-15-16 Weight .................................................................. . 210-15-16 Capacities............................................................. . 210-15-17 Dimensions........................................................... . 210-15-18
Group 10 - Combine and Component Identification Interpreting Machine Serial Number...................... 210-10-1 Identification Numbers.......................................... . 210-10-2
Unified Inch Bolt and Screw Torque Values ......... . 210-15-21 Metric Bolt and Screw Torque Values................... . 210-15-22
Machine Identification Plate.................................. . 210-10-2
Group 20 - Diagnostic and Testing Procedures
Machine Identification Plate Location .................... 210-10-2
Troubleshooting.................................................... . 210-20-1
TM805419 (01.12.2018)
210-1
S540, S550, S660, S670, S680 and S690 Combines
Safety
Group 05 Safety Recognize Safety Information
T81389-UN: Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. DX,ALERT-19-19980929
Handle Fluids Safely—Avoid Fires
TS227-UN: Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. DX,FLAME-19-19980929
Prepare for Emergencies
TS291-UN: First Aid Kit
Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. DX,FIRE2-19-19930303
TM805419 (01.12.2018)
210-05-1
S540, S550, S660, S670, S680 and S690 Combines
Safety
Prevent Battery Explosions
TS204-UN: Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). DX,SPARKS-19-19930303
Prevent Acid Burns
TS203-UN: Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by:
Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure. If you spill acid on yourself:
Flush your skin with water. Apply baking soda or lime to help neutralize the acid. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed:
Do not induce vomiting. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). Get medical attention immediately. DX,POISON-19-19930421
Handle Chemical Products Safely
TS1132-UN: Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. (See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.) DX,MSDS,NA-19-19930303
TM805419 (01.12.2018)
210-05-2
S540, S550, S660, S670, S680 and S690 Combines
Safety
Handle Starting Fluid Safely
TS1356-UN: Store Safely
Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables. To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location. Do not incinerate or puncture a starting fluid container. Do not use starting fluid on an engine equipped with glow plugs or an air intake heater. DX,FIRE3-19-20140314
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.
X9811-UN: High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.
Park Machine Safely
DX,FLUID-19-20111012
TS230-UN: Remove the Key
Before working on the machine:
Lower all equipment to the ground. Stop the engine and remove the key. Disconnect the battery ground strap. Hang a "DO NOT OPERATE" tag in operator station. DX,PARK-19-19900604
TM805419 (01.12.2018)
210-05-3
S540, S550, S660, S670, S680 and S690 Combines
Safety
Support Machine Properly
TS229-UN: Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual. DX,LOWER-19-20000224
Wear Protective Clothing
TS206-UN: Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. DX,WEAR-19-19900910
Protect Against Noise
TS207-UN: Noise Exposure
Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. DX,NOISE-19-19930303
Work in Clean Area
T6642EJ-UN: Clean Work Area
Before starting a job:
Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attempt shortcuts. DX,CLEAN-19-19900604
TM805419 (01.12.2018)
210-05-4
S540, S550, S660, S670, S680 and S690 Combines
Safety
Work In Ventilated Area
TS220-UN: Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. DX,AIR-19-19990217
Illuminate Work Area Safely
TS223-UN: Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. DX,LIGHT-19-19900604
Service Machines Safely
TS228-UN: Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. DX,LOOSE-19-19900604
Construct Dealer-Made Tools Safely
LX1016749-UN: Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship. Do not weld tools unless you have the proper equipment and experience to perform the job. DX,SAFE,TOOLS-19-19971010
TM805419 (01.12.2018)
210-05-5
S540, S550, S660, S670, S680 and S690 Combines