John Deere Combines 9570 STS, 9670 STS, 9770 STS, 9870 STS Repair Service Manual (TM101919)
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Model:
Complete service repair manual for John Deere Combines 9570 STS, 9670 STS, 9770 STS, 9870 STS, with workshop information to maintain, repair, and rebuild.
John Deere Combines 9570 STS, 9670 STS, 9770 STS, 9870 STS 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.
TM101919 English - John Deere Combines 9570 STS, 9670 STS, 9770 STS and 9870 STS Technical Manual (Repair).PDF
tm101914 Portuguese - 9570 STS, 9670 STS, 9770 STS and 9870 STS Combine Repair.pdf
tm101954 Russian - Reparação das Colheitadeiras 9570 STS™, 9670? S?S™, 9770 STS™ e 9870 STS™
tm101959 Russian - Ремонт комбайнов 9570 STS™, 9670 STS™, 9770??S?S™ и 9870 STS
ctm103554 Portuguese - 100 Series Hydraulic Cylinders CTM.pdf
Total Pages: 2,476 pages
File Format: PDF (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 Repair
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 Repair
Transmission And Differential-Three Speed Transmission
Hydrostatic System-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-Heavy Duty
Cam Lobe Motor
Tires And Wheels
Power Steering And Brakes
Steering
Brakes
Brakes-Two-Range Automatic Transmission
Hydraulic Repair
Hydraulic Reservoir
Hydraulic Pumps
Hydraulic Valves
Hydraulic Cylinders
Motors
Accumulator
Separator Shell
Gull Wing Doors
Operator Station Repair
Air Conditioning System (R134a)
System Components
Cab
Feeder House Repair
Conveyor
Top Shaft And Slip Clutch
Feeder House Drives And Reverser Gear Case
Lateral Tilt Cylinder
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 Repair
Grain Tank Cross Augers
Unloading Auger System Drives
Vertical Unloading Auger And Lower Gear Case
Horizontal Unloading Auger And Gear Case
Clean Grain Elevator
Grain Tank And Extensions
Engine Gear Case And Control Valve Repair
Engine Gear Case And Valve
Dealer Fabricated Tools
Dealer Fabricated Tools
TABLE OF CONTENTS
Section 10: General................33
Group 05: Safety................33
Recognize Safety Information................37
Understand Signal Words................38
Handle Fluids Safely—Avoid Fires................39
Prevent Battery Explosions................277
Handling Batteries Safely................278
Prepare for Emergencies................43
Prevent Acid Burns................44
Avoid High-Pressure Fluids................46
Service Accumulator Systems Safely................47
Wait Before Opening High-Pressure Fuel System................48
Park Machine Safely................49
Support Machine Properly................50
Wear Protective Clothing................51
Work in Clean Area................52
Service Machines Safely................53
Work In Ventilated Area................54
Illuminate Work Area Safely................55
Replace Safety Signs................56
Use Proper Lifting Equipment................57
Remove Paint Before Welding or Heating................58
Avoid Heating Near Pressurized Fluid Lines................59
Service Tires Safely................1079
Avoid Harmful Asbestos Dust................61
Practice Safe Maintenance................62
Construct Dealer-Made Tools Safely................64
Use Proper Tools................65
Decommissioning — Proper Recycling and Disposal of Fluids and Components................66
Use Adequate Service Facilities................67
Live With Safety................68
Servicing Electronic Control Units................69
Welding Near Electronic Control Units................70
Keep Electronic Control Unit Connectors Clean................71
Group 10: Specifications................2400
Ground Speeds (Fast Idle) Two Speed Four Wheel Drive................74
Turning Radius................76
Operating Speeds - 9570 STS Combine................77
Specifications - 9570 STS Combine................80
Dimensions - 9570 STS Combine................83
Dimension Reference Points - 9570 STS Combine................85
Operating Speeds - 9670 STS, 9770 STS Combines................86
Specifications - 9670 STS................89
Specifications - 9770 STS................92
Dimensions - 9670 STS, 9770 STS Combines................95
Dimension Reference Points - 9670 STS, 9770 STS Combines................97
Operating Speeds - 9870 STS Combine................98
Specifications - 9870 STS Combine................101
Dimensions - 9870 STS Combine................104
Dimension Reference Points - 9870 STS Combine................106
Metric Bolt and Screw Torque Values................107
Unified Inch Bolt and Screw Torque Values................109
Sealants and Adhesives Cross-Reference Chart................111
Face Seal Fittings Assembly and Installation—All Pressure Applications................113
Metric Face Seal And O-Ring Stud End Fitting Torque Chart—Standard Pressures................114
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications................116
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures................118
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications................120
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications................122
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications................123
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications................124
External Hexagon Port Plug Torque Chart................125
Prevent Hydraulic System Contamination................139
Check Oil Lines and Fittings................140
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems................141
Group 15: Tune-Up and Adjustment................132
Tune-Up and Adjustment................132
Care and Maintenance of Belts................134
Defective Belts................136
Prevent Hydraulic System Contamination................139
Check Oil Lines and Fittings................140
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems................141
Group 20: Fuels And Lubricants................35
Handle Fuel Safely—Avoid Fires................143
Handling and Storing Diesel Fuel................145
Diesel Fuel................145
BioDiesel Fuel................147
Lubricity of Diesel Fuel................149
Testing Diesel Fuel................150
Diesel Engine Coolant (engine with wet sleeve cylinder liners)................151
Operating in Warm Temperature Climates................153
Supplemental Coolant Additives................154
Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER................155
Testing Diesel Engine Coolant................157
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III................158
Diesel Engine Oil — Tier 3 and Stage III................160
Oilscan™ and CoolScan™................162
Hydrostatic Drive System, Main Hydraulic System and Main Engine Gearcase Oils................163
Transmission (Non Two Range Automatic Transmission Machines), Final Drives, Loading Auger, Primary Countershaft and Two-Speed Separator Drive Gear Cases................164
Feeder House Reverser Gear Case................166
Grease................167
Brake Fluid (Non Two Range Automatic Transmission Machines)................169
Lubricant Storage................170
Alternative and Synthetic Lubricants................171
Mixing of Lubricants................172
Section 20: Engine................173
Group 05: Remove And Install Engine................173
Essential or Recommended Tools................2396
Specifications................2400
Other Material................2399
John Deere Engine Repair—Use CTM................245
Remove Engine—6.8 L................173
Install Engine—6.8 L................173
Remove Engine—9.0 L................173
Install Engine—9.0 L................173
Remove Engine—13.5 L................173
Install Engine—13.5 L................173
Remove and Install Flywheel Pilot Bearing................206
Group 10: Cooling System................173
Essential or Recommended Tools................2396
Specifications................2400
John Deere Engine Repair—Use CTM................245
Rotary Screen Drive................212
Rotary Screen Idler Arm and Sheaves................214
Remove and Install Upper and Lower Air Scoops................215
Remove and Install Rotary Screen................217
Adjusting Rotary Screen Knife Comb................220
Remove Radiator—6.8 L Engine................173
Install Radiator—6.8 L Engine................173
Remove Radiator—9.0 L and 13.5 L Engines................173
Install Radiator—9.0 L and 13.5 L Engines................173
Test Radiator................237
Test Radiator Cap................238
Replace Thermostats................239
Repair or Replace Water Pump................240
Section 30: Fuel And Air Repair................241
Group 05: Air Intake System................241
Other Material................2399
Specifications................2400
John Deere Engine Repair—Use CTM................245
Remove and Install Turbocharger................246
Turbocharger Repair................247
Remove and Install Charge Air Cooler................248
Cleaning the Charge Air Cooler................253
Group 10: Diesel Fuel System................241
Other Material................2399
Specifications................2400
Remove and Install Fuel Tank................257
Remove and Install Fuel Tank Shut-Off Valve and Drain Valve—9570, 9670, and 9770................261
Remove and Install Fuel Tank Shut-Off Valve—9870................264
Remove and Install Fuel Tank Strainer and Breather................265
Replace Cold Weather Starting Aid Can................267
Remove and Install Cold Weather Starting Aid................268
Section 40: Electrical System................270
Group 05: Batteries................270
Prevent Battery Explosions................277
Handling Batteries Safely................278
Prevent Damage to Electrical Systems................280
Checking Electrolyte Specific Gravity................281
Battery Replacement................283
Remove and Install Batteries................284
Connecting Booster Batteries................287
Charging Batteries................288
Connecting Battery Cables................290
Group 10: Harness And Connector Repair................270
Essential or Recommended Tools................2396
Other Material................2399
Use Electrical Insulating Compound................302
Using High-Pressure Washers................303
Electrical System Visual Inspection................304
Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer Controlled Systems................305
Electrical Connector / Wiring Harness Handling and Repair................306
Repair Procedure R-A................307
Repair Procedure R-B................312
Repair Procedure R-C................316
Repair Procedure R-D................321
Repair Procedure R-E................324
Repair Procedure R-F................328
Repair Procedure R-G................332
Repair Procedure R-I................335
Repair Procedure R-J................338
Repair Procedure R-K................343
Repair Procedure R-M................346
Repair Procedure R-N................350
Repair Procedure R-AE................354
Repair Procedure R-AF................358
Repair Procedure R-AG................361
Repair Procedure R-AH................364
Repair Procedure R-AI................366
Repair Procedure R-AJ................369
Repair Procedure R-AK................374
Repair Procedure R-AL................377
Group 15: Wire Harness Routing................271
Replace Harness................382
Cab Main Wiring Harness................383
Left-Hand Main Wiring Harness................384
LC1 Wiring Harness................385
LC2 Wiring Harness................386
Self-Leveling Shoe Wiring Harness................387
Right-Hand Main Wiring Harness................388
Engine Deck Wiring Harness—6.8 L and 9.0 L................389
Engine Deck Wiring Harness—13.5 L................390
Group 20: Controllers and Power Distribution................271
Fuse Identification................394
Remove and Install Cab Power Module (CPM)................397
Remove and Install Right and Left Power Modules................398
Programming Control Units................399
Group 25: Lighting................271
Safety Rules When Replacing Halogen Bulbs................403
Safety Rules When Replacing High Intensity Discharge (HID) Xenon Bulbs................404
Cab Head Light Bulb Replacement and Adjustment................405
Remove and Install High Intensity Discharge (HID-Xenon) Lights (Optional)................407
Remove and Install High Intensity Discharge (HID-Xenon) Ballasts................410
Auxiliary Field, Access Door, Grain Tank, Unload Auger and Work Light Bulb Replacement................411
Side Finder (Optional) Light Bulb Replacement................412
Front Turn Signal, Tail and Side Light Bulb Replacement................413
Harzard/Warning Light Bulb Replacement................414
Cleaning Shoe Light Bulb Replacement................415
Turn Signal Light Bulb Replacement................416
Dome Light Bulb Replacement................417
Group 30: Operators Station................272
Other Material................2399
Specifications................2400
Instruments And Controls Identification................421
Remove and Install Overhead Panel................423
Remove and Install Right-Hand Overhead Panel................425
Remove and Install Light Panel Dimmer Switch................426
Remove and Install Overhead Panel and Right-Hand Overhead Panel Rocker Switches................427
Remove and Install ClimaTrak ClimaTrak is a trademark of Deere & Company Automatic Air Conditioning/Heater Temperature Control Switch and Fan Switch................272
Remove and Install Radio................430
Remove and Install Radio Speaker................432
Remove and Install Radio Antenna................433
Replace Cornerpost Main Circuit Board................435
Remove Header Control Module................439
Remove VisionTrak VisionTrak is a trademark of Deere & Company Module and Digital Tachometer Module................272
CommandTouch Console Controls................441
Remove and Install CommandTouch Console................443
Remove and Install Armrest Display Unit................445
Remove and Install Header and Separator Engage Switches................446
Remove and Install Backlighting Driver................447
Remove and Install Dial-A-Speed and Active Header Control Switches................449
Remove and Install CommandTouch Console Switch Panel................451
Replace Neutral Safety Switch................454
Remove and Install Multi-Function Handle................456
Remove and Install Start Switch................458
Remove and Install Starting Aid Switch................460
Remove and Install Turn Signal/Side Finder Light Switch................461
Remove and Install Horn Switch................462
Remove and Install Remote Mirrors (Optional)................463
Remove and Install Remote Mirror Switch (Optional)................464
Group 35: Sensors And Switches................273
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
Shaft Speed Sensor Locations................469
Remove and Install Ground Speed Sensor................471
Remove and Install Low Shaft Speed Sensor................472
Remove and Install STS Rotor Speed Sensor................473
Remove and Install Full Grain Tank Sensor................475
Remove and Install Straw Spreader Speed Sensor................476
Remove and Install Tailings Sensor................480
Remove and Install (Shoe/Separator) VisionTrak VisionTrak is a trademark of Deere & Company Sensors................273
Remove and Install Concave Position Sensor................482
Remove and Install Header Height and Lateral Tilt Control Sensors................483
Remove and Install Folding Unloading Auger Position Sensor................485
Remove And Install Multi-Function Handle Feed Rate Sensor................488
Remove and Install Hydraulic Reservoir Temperature Sensor................495
Remove and Install Coolant Temperature Sensor................496
Remove and Install Fuel Level Sensor................499
Remove and Install Park Brake Switch................500
Remove and Install Air Filter Restriction Switch................501
Remove and Install Fuel Transfer Pump Pressure Sensor—6.8 L Engine and 9.0 L Engine................502
Remove and Install High and Low Fuel Pressure Sensors—13.5 L Engine................503
Remove and Install Engine Gear Case Temperature and Pressure Switches................504
Remove and Install Hydro Charge Pressure Switch................505
Remove and Install Engine Oil Pressure Sensor................506
Remove and Install Compressor Inlet Temperature Sensor................508
Remove and Install Pump Position Sensor—6.8 L Engine and 9.0 L Engine................509
Remove and Install Cam Position Sensor—13.5 L Engine................510
Remove and Install Engine Speed Sensor................511
Remove and Install Exhaust Gas Recirculation (EGR) Exhaust Gas Temperature and Fresh Air Temperature Sensors................512
Remove and Install Intake Manifold Pressure and Exhaust Gas Recirculation (EGR) Mixed Gas Temperature Sensor................514
Remove and Install Turbocharger Speed Sensor................516
Remove and Install Fuel Temperature Sensor................517
Remove and Install Fuel Rail Pressure Sensor—6.8 L Engine and 9.0 L Engine................519
Remove and Install Switches in the Ground Level Switch Bank................521
Remove and Install Wheel Angle Sensor................522
Remove and Install Back-Up Alarm Switch................527
Back-Up Alarm—9870................528
Back-Up Alarm—9570, 9670, 9770................529
Group 40: Wiper................274
Specifications................2400
Remove and Install Wiper Motor................532
Adjust Windshield Wiper................536
Remove and Install Windshield Washer................538
Group 45: Alternator................274
Essential or Recommended Tools................2396
Specifications................2400
John Deere Engine Accessories—Alternator Repair—Use CTM77................543
Remove and Install Alternator And Alternator Belt................544
Remove and Install Alternator Pulley................546
Group 50: Starting Motor................274
Essential or Recommended Tools................2396
Specifications................2400
John Deere Starting Motor Repair................550
Remove and Install Starting Motor................551
Group 55: GreenStar Components................274
Specifications................2400
Other Material................2399
Remove and Install GreenStar Mass-Flow Sensor................557
Remove and Install GreenStar Moisture Sensor................561
Disassemble and Assemble GreenStar Moisture Sensor................562
Remove and Install GreenStar Moisture Sensor Actuator................564
Remove and Install GreenStar Moisture Sensor Circuit Board................568
Remove and Replace GreenStar Moisture Sensor Lower Cell Assembly................570
Disassemble and Assemble Position Receiver................586
Remove and Install Position Receiver................588
Section 50: Power Train Repair................589
Group 05: Transmission And Differential—Three Speed Transmission................589
Other Material................2399
Specifications................2400
Remove and Repair Shifter Forks and Shifter Cam................597
Install Shifter Forks and Shifter Cam................599
Remove and Install Transmission Lube Pump................602
Remove and Install Suction Screen................605
Remove Transmission................606
Transmission Components................609
Transmission Recondition................612
Disassemble and Repair Transmission................613
Assemble Transmission................622
Install Transmission................626
Remove and Install Gearshift Lever and Linkage................628
Adjust Gearshift Linkage................630
Group 10: Hydrostatic System—Three Speed Transmission................589
Essential or Recommended Tools................2396
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Serial Number Plate................890
Clean Hydrostatic Motor and Pump................640
Flushing the Hydrostatic System................641
Remove and Install Hydrostatic Motor................642
Disassemble Hydrostatic Motor................644
Inspect Parts................655
Lack of Lubrication................656
Abrasive Contamination................657
Cavitation................658
Over Speeding................659
Inspect Thrust Plate................660
Inspect Fixed Swashplate................661
Inspect Piston Slipper................662
Inspect Piston Retainer................664
Inspect Cylinder Block................666
Inspect Bearing Plate................667
Inspect Valve Plate................670
Inspect Bearing and Race................673
Inspect Servo Piston................674
Inspect Drive Shaft................675
Replace Cylinder Block Spring................676
Assemble Motor................677
Remove and Install Motor Valve Block (Manifold)................691
Repair Motor Valve Block................693
Remove and Install Hydrostatic Pump................695
Disassemble Drive Pump................699
Assemble Drive Pump................716
Replace High-Pressure Line Center Pivot O-Rings................736
Disassemble and Assemble End Cover................737
Repair Displacement Control Valve................739
Disassemble and Assemble DisplacementControl Valve with Feed Rate (Optional)................590
Electronic Proportional Displacement Control Valve Neutral Adjustment................743
Remove and Install Charge Pump................747
Repair Charge Pump................749
Remove and Install Control Cable................751
Adjust Hydrostatic Neutral Linkage................753
Adjust Mechanical Displacement Control Valve Neutral................754
Start-Up Procedure After Hydrostatic System Repair................756
Group 15: Transmission and Differential—Two-Range Automatic Transmission................590
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
Drain Oil................776
Remove Two-Range Automatic Transmission................777
Transmission Components—Overview................783
Disassemble Two-Range Automatic Transmission................785
Remove Brake Assemblies................788
Brake Assemblies—Exploded View................791
Disassemble Brake Assemblies................793
Assemble Brake Assemblies................799
Install Brake Assemblies................806
Remove Differential Module................809
Disassemble Differential Module (With Differential Lock)................813
Differential Module (With Differential Lock)—Exploded View................819
Assemble Differential Module (With Differential Lock)................821
Install Differential Module................829
Remove Gear-Shift Planetary Drive With Clutch................832
Disassemble and Assemble Gear-Shift Planetary Drive With Clutch................837
Install Gear-Shift Planetary Drive With Clutch................860
Remove Countershaft................867
Repair Countershaft................870
Countershaft—Exploded View................873
Install Countershaft................874
Assemble Two-Range Automatic Transmission................879
Install Two-Range Automatic Transmission................882
Group 20: Hydrostatic Drive Pump—Two-Range Automatic Transmission................591
Specifications................2400
General View................948
Serial Number Plate................890
Clean Variable Pump................891
Remove and Install Hydrostatic Pump (Two-Range Automatic Transmission)................892
Replace Drive Shaft Seal................895
Replace Boost Pump Seal................900
Replace Control Piston Cover Seals................903
Remove and Install Control Unit................907
Disassemble Pump................911
Disassemble Cylinder Assembly................917
Disassemble Control Piston................919
Hydrostatic Drive Pump Inspection Notes................968
Assemble Pump................926
Install Rotary Group................933
Adjust Zero Position................940
Group 25: Hydrostatic Drive Motor—Two-Range Automatic Transmission................592
Essential or Recommended Tools................2396
Specifications................2400
Remove And Install Hydrostatic Drive Motor................945
General View................948
Replace Cover Plate Seal................949
Replace Control Body Seals................951
Disassemble Port Plate................953
Assemble Port Plate................959
Disassemble Rotary Group................962
Inspection Notes................968
Assemble Rotary Group................972
Adjust Rotary Group................980
Group 30: Single Reduction Final Drive—Heavy Duty................592
Essential Tools or Recommended Tools................985
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Remove and Install Final Drive................990
Disassemble and Assemble Final Drive................995
Adjust Spindle Bearing................1008
Group 35: Cam Lobe Motor................592
Essential or Recommended Tools................2396
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Flushing Cam Lobe Motors................1020
Remove Cam Lobe Motor................1021
Install Cam Lobe Motor................1023
Remove and Install Cam Lobe Motor Control Valve................1025
Disassemble and Assemble Cam Lobe Motor Control Valve................1028
Remove and Install Steering Yoke................1030
Disassemble and Assemble Pivot Pins, Bushings, and Seals................1038
Remove and Install Solenoid Valve and Valve Block................1041
Remove and Install Displacement Control Valve................1046
Remove and Install Cam and Piston Carrier................1049
Remove and Install Stack Valve Seals................1056
Remove and Install Axle Bearings and Seals................1061
Group 40: Tires And Wheels................593
Essential or Recommended Tools................2396
Service Equipment and Tools................1990
Specifications................2400
Service Tires Safely................1079
Care and Service of Tires................1080
Using Liquid Weight................1082
Jacking Locations................1083
Remove and Install Wheel................1084
Drive Wheel Bolt Torque................1086
Dual Wheels Bolt Torque................1087
Rear Wheel Bolt Torque................1088
Install Axle Extension Tubes................1089
Install Dual Wheels and Truss Rod................1094
Section 60: Power Steering And Brakes................1101
Group 05: Steering................1101
Essential or Recommended Tools................2396
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Steering Pump Repair................1109
Remove Steering Valve................1112
Steering Valve................1112
Disassemble Steering Valve................1114
Assemble Steering Valve................1119
Install Steering Valve................1125
Electro-Hydraulic Steering Valve and Flowmeter—Exploded View................1127
Remove and Install Flowmeter................1129
AUTOTRAC Assisted Steering Flowmeter—Exploded View................1130
Steering Column Components................1131
Disassemble and Assemble Steering Column................1133
Replace Telescoping Shaft Bearings................1139
Remove and Install Steering Cylinder................1141
Steering Cylinder—Exploded View................1146
Toe-In Adjustment................1147
Remove and Install Steering Tie Rod Joint................1148
Remove and Install Tie Rod End................1150
Remove and Install Rear Spindle Assembly—Non-Powered................1101
Disassemble and Assemble Rear Spindle Assembly—Non-Powered................1101
Remove and Install Rear Axle Pivot Bushings................1162
Rear Axle Adjustment................1167
Group 10: Brakes................1101
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Deglazing Brake Linings................1173
Remove Brake Drum................1174
Remove Brake Shoe................1176
Repair Brakes................1178
Assemble Brakes................1182
Install Brake Drum................1184
Remove and Install Master Cylinder................1185
Disassemble and Assemble Master Cylinder (Double Bleed Screw)................1186
Brake Fluid Reservoir................1188
Adjusting Master Cylinder................1189
Bleeding Brake System—Double Bleed Screw................1190
Remove and Install Slave Cylinders................1195
Disassemble and Assemble Slave Cylinder................1196
Disassemble and Assemble Brake Pedals................1218
Disassemble and Assemble Parking Brake Pedal................1204
Adjust Park Brake Pedal................1213
Group 15: Brakes—Two-Range Automatic Transmission................1102
Specifications................2400
Bleed Service Brakes................1216
Disassemble and Assemble Brake Pedals................1218
Disassemble and Assemble Oil Pressure Regulating Valve (Service Brake Circuit)................1220
Check Brake Disk Thickness................1225
Section 70: Hydraulic Repair................1227
Group 05: Hydraulic Reservoir................1227
Essential or Recommended Tools................2396
Specifications................2400
Remove and Install Reservoir................1233
Flushing the Hydraulic System................1239
Flushing the Reel/Belt Pickup Drive System................1241
Group 10: Hydraulic Pumps................1227
Essential or Recommended Tools................2396
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Remove Main Hydraulic Pump................1247
Marking Hydraulic Pump................1249
Disassemble Hydraulic Pump................1250
Replace Seal................1252
Triple Main Hydraulic Pump—Exploded View................1253
Quad Main Hydraulic Pump—Exploded View................1255
Assemble Triple Main Hydraulic Pump................1257
Assemble Quad Main Hydraulic Pump................1259
Install Main Hydraulic Pump................1261
Proportionator Pump—Exploded View................1262
Assemble Proportionator Pump................1264
Reel/Belt Pickup and Straw Spreader Pump—Exploded View................1266
Remove And Install Reel/Belt Pickup Pump Drive................1268
Disassemble and Assemble Reel/Belt Pickup Pump Drive................1272
Remove Straw Spreader Pump................1277
Install Straw Spreader Pump................1280
Disassemble Reel/Belt Pickup Straw Spreader Pump................1282
Assemble Reel/Belt Pickup and Straw Spreader Pump................1285
Group 15: Hydraulic Valves................1227
Essential or Recommended Tools................2396
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Remove and Install Left Front Valve Block................1292
Disassemble and Assemble Left Front Valve Block................1294
Remove and Install Right Forward Valve Block................1296
Disassemble and Assemble Right Forward Valve Block................1298
Disassemble and Assemble Five Speed Feeder House Drive Control Valve................1300
Remove and Install Straw Spreader Control Valve Block................1302
Disassemble and Assemble Straw Spreader Flow Control Valve................1304
Valve Stack Identification................1306
Remove and Install Hydraulic Valve Stack (HIC)................1307
Disassemble and Assemble Hydraulic Valve Stack (HIC)................1309
Remove and Install Header Height Control Valve................1313
Remove and Install Accumulator Shut-off Valve................1315
Remove and Install Transmission Control Valve................1316
Remove and Repair Valves From Transmission Control Valve................1321
Transmission Control Valve—Exploded View................1323
Install Valves In Transmission Control Valve................1325
Remove and Install Hydraulic Service Brake Valve................1327
Disassemble and Assemble Hydraulic Service Brake Valve................1329
Adjust Hydraulic Service Brake Valve................1330
Feeder House Multi-Coupler Valve Identification................1331
Disassemble, Inspect and Assemble Feeder House Multi-Coupler................1332
Group 20: Hydraulic Cylinders................1228
Specifications................2400
Remove and Install Header Lift Cylinder................1338
Disassemble and Assemble Header Lift Cylinder—Style A................1340
Disassemble and Assemble Header Lift Cylinder—Style B................1342
Remove and Install Unloading Auger Swing Cylinder................1344
Unloading Auger Swing Cylinder Exploded View................1346
Adjust Unloading Auger Swing Cylinder................1348
Remove and Install Unloading Auger Drive Cylinder................1350
Disassemble and Assemble Steering Cylinder................1352
Group 25: Motors................1229
Remove and Install Straw Spreader Motor................1360
Remove and Install Wide Spread Tailboard Motors................1364
Group 30: Accumulator................1229
Essential or Recommended Tools................2396
Accumulator (General Information)................1369
Checking Accumulator Pressure................1370
Header Float Accumulator Precharge Pressure................1372
Section 80: Separator Shell................1374
Group 05: Gull Wing Doors................1374
Other Material................2399
Specifications................2400
Remove and Install Gull Wing Doors................1378
Remove and Install Rear Wall Panel................1380
Composite Panel Repair................1382
Align Gull Wing Doors................1386
Remove and Install Engine Platform Ladder................1389
Section 90: Operator Station Repair................1390
Group 05: Air Conditioning System (R134a)................1390
Essential or Recommended Tools................2396
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Service Parts Kits................1401
Hose and Tubing O-Ring Connection Torques................1402
Discharge and Recovery of Air Conditioning Refrigerant................1403
Remove and Install Compressor................1404
Test Volumetric Efficiency................1407
Leak Testing Air Conditioning System With Dye................1410
Test Shaft Seal Leakage................1412
Disassemble and Assemble Compressor Clutch................1414
Check Clutch Hub Clearance................1416
Inspect Compressor Manifold................1417
Disassemble, Inspect, and Assemble Compressor................1418
Remove and Install Compressor Relief Valve................1421
System Information................1422
Flush Air Conditioning System................1424
Purge Air Conditioning System................1428
Evacuate Air Conditioning System................1429
Compressor Oil Information................1432
Determine Correct Oil Charge................1433
Check Refrigerant Oil Charge................1435
Charge Air Conditioning System................1436
Group 10: System Components................1390
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
Air Conditioning System With Precleaner (General Information)................1441
Remove and Install Receiver/Dryer................1442
Remove and Install Recirculator Motor................1443
Remove and Install Recirculator Fan Motor Driver................1444
Remove and Install Blower Motor................1445
Remove and Install Temperature Control Door Actuator................1446
Remove and Install Heater Core................1447
Remove Condenser................1449
Repair Condenser................1452
Install Condenser................1453
Replace Evaporator................1455
Replace Expansion Valve................1457
Remove and Install Evaporator Temperature Sensor................1459
Replace Low Pressure Switch................1460
Replace High Pressure Switch................1461
Replace Air Temperature Sensors................1462
Group 15: Cab................1391
Specifications................2400
Remove and Install Cab Windshield................1465
Remove Cab................1473
Install Cab................1482
Replace Rear Window................1490
Remove and Install Cab Outer Roof................1491
Remove and Install Cab Inner Roof................1493
Remove and Install Cab Headliner................1499
Remove and Install Operator's Seat................1501
Remove and Install Armrest Control Pivot................1506
Remove and Install Operator Presence Switch................1508
Operator Seat—Exploded View................1510
Operator Seat Air Suspension Assembly—Exploded View................1512
Disassemble and Assemble Operator Seat Air Suspension Assembly................1514
Remove and Install Cab Door................1519
Disassemble and Assemble Cab Door................1520
Cab Door Latch Striker................1522
Section 110: Feeder House Repair................1524
Group 05: Conveyor................1524
Other Material................2399
Specifications................2400
Remove and Install Feeder House................1530
Feeder House Conveyor Chain—Adjust (Style A)................1532
Feeder House Conveyor Chain—Adjust (Style B)................1534
Remove and Install Conveyor Chain................1535
Measure Conveyor Chain Wear................1538
Removing Conveyor Chain Link................1539
Replace Conveyor Chain Slats................1541
Replace Conveyor Chain Wear Strips................1543
Adjust Drum Height................1546
Remove and Install Conveyor Drum—Style A................1547
Remove and Install Conveyor Drum—Style B................1551
Remove and Install Sub-Floor Assembly................1555
Remove and Install Mid-Floor Assembly—Style A................1557
Remove and Install Mid-Floor Assembly—Style B................1559
Single Point Latching Level Land—Exploded View................1560
Remove and Install Feed Plate................1562
Adjust Feed Plate Assembly................1565
Feed Plate Support—Exploded View................1567
Group 10: Top Shaft And Slip Clutch................1524
Essential Or Recommended Tools................1570
Other Material................2399
Specifications................2400
Remove Top Shaft Slip Clutch................1573
Disassemble and Assemble Top Shaft Slip Clutch................1575
Install Top Shaft Slip Clutch................1580
Remove and Install Top Shaft Supports................1582
Disassemble and Assemble Top Shaft................1588
Group 15: Feeder House Drives and Reverser Gear Case................1524
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
Remove and Install Variable Drive Countershaft................1604
Disassemble and Assemble Upper Variable Drive Countershaft................1616
Disassemble and Assemble Standard Capacity Fixed Speed Countershaft................1626
Remove, Repair and Install Variable Drive Sheaves and Cams—Style A................1628
Remove, Repair and Install Variable Drive Sheaves and Cams—Style B................1635
Remove and Install Multi-Speed Feeder House Countershaft................1647
Remove and Install Fixed Drive Sheave................1650
Remove and Install Reverser Gear Case................1652
Remove and Install Oil Cooler................1654
Feeder House Reverser Gear Case—Exploded View................1656
Disassemble and Assemble Feeder House Reverser Gear Case................1658
Disassemble and Assemble Reverser Gear Case Oil Pump................1675
Remove and Install Reverser Shift Piston................1681
Remove and Install Lower Shaft................1685
Disassemble and Assemble Fixed Speed Drive Tightener................1688
Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides................1690
Feeder House Variable Speed Belt—Adjustment................1692
Replace Variable Speed Feeder House Belt................1697
Remove and Install Feeder House Multi-Speed Drive Belt................1701
Replace and Adjust Fixed Speed Feeder House Belt................1703
Group 20: Lateral Tilt Cylinder................1525
Lateral Tilt CylinderHoses and Fittings................1525
Lateral Tilt Cylinder—Exploded View................1706
Remove and Install Lateral Tilt Cylinder................1707
Group 25: Lateral Tilt Frame................1525
Other Material................2399
Specifications................2400
Lateral Tilt Frame and Beam................1712
Remove and Install Lateral Tilt Frame................1714
Remove and Install Lateral Tilt Beam................1718
Adjust Single Point Latching................1723
Lateral Tilt Beam with Single Point Latching................1726
Adjust Fore-Aft Turnbuckles................1727
Remove Fore-Aft Tilt Frame................1729
Install Fore-Aft Tilt Frame................1732
Group 30: Five Speed Feeder House Drive Gear Case................1526
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
General Repair Procedures—Five Speed Gear Case................1747
Remove and Install Five Speed Feeder House Drive Gear Case................1749
Cross-Sectional View—Five Speed Feeder House Drive Gear Case................1754
Cross-Sectional View—Gear Case Output Shaft................1756
Cross-Sectional View—Gear Case Countershaft................1758
Disassemble Five Speed Feeder House Drive Gear Case................1760
Disassemble and Assemble Gear/Clutch Assemblies................1768
Assemble Five Speed Feeder House Drive Gear Case................1774
Section 120: Separator................1786
Group 05: Separator Repair................1786
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
Remove And Install Feed Accelerator And Shaft................1803
Remove and Install Feed Accelerator Wear Strips................1812
Remove And Install Separator Top Covers................1814
Remove And Install Separator Rails................1819
Remove And Install Rotor Front Bearing................1830
Remove and Install Stone Trap Door................1836
Remove And Install Rotor................1838
Replace Rear Bulkhead (Rotor Drive Gear Case Support)................1845
Remove And Install Rotor Torque Sensing—Driven................1846
Disassemble And Assemble Rotor Torque Sensing—Driven................1850
Remove and Install Rotor Drive Gear Case................1861
Disassemble and Assemble Rotor Drive Gear Case................1865
Remove And Install Discharge Beater Grate Section................1872
Remove And Install Discharge Beater Grate Frame................1877
Remove And Install Discharge Beater................1883
Remove and Install Discharge Beater Drive Hub................1893
Remove and Install Discharge Beater Housing................1895
Remove And Install Separator Grates................1900
Remove and Install Concave Sections................1902
Adjust Concave Level................1911
Remove And Install Concave Adjusting Motor................1917
Remove And Install Concave Adjusting Tube................1918
Remove and Install Front Bulkhead................1924
Remove and Install Center Bulkhead................1927
Repair Separator Rotor Shell................1931
Remove And Install Threshing Elements And Tines................1932
Threshing Element and Separator Tine Location (9570)................1934
Threshing Element And Separator Tine Location (15 Element Configuration)................1935
Threshing Element and Separator Tine Location (24 Element Dense Pack Configuration)................1937
Remove And Replace RIVNUT Threaded Inserts................1939
Remove And Install Rotor Feed Flights................1942
Static Balance Rotor................1945
Aligning Rotor Drive Bulkhead................1949
Group 10: Separator Drives................1787
Essential or Recommended Tools................2396
Specifications................2400
Remove and Install Right-Hand Front Jackshaft................1956
Remove and Install Right-Hand Rear Jackshaft................1959
Remove and Install Primary Countershaft Bearing................1964
Remove and Install Primary Countershaft—Style A................1967
Remove and Install Primary Countershaft—Style B................1971
Remove and Install Primary Drive Shafts—Style A................1974
Remove and Install Primary Drive Shafts—Style B................1980
Replace Drive Shaft Carrier Bearing—Style A................1986
Group 15: Residue Disposal................1787
Service Equipment and Tools................1990
Other Material................2399
Specifications................2400
Straw Chopper Housing................1993
Remove Straw Chopper................1996
Remove and Install Chopper Raise/Lower Actuator................2000
Install Straw Chopper................2002
Chopper Blades—Replacement and Configuration (9570 STS)................2006
Chopper Blades—Replacement and Configuration (9670, 9770 and 9870 STS)................2011
Replace Knife Blades................2015
Remove and Install Easy Adjust Knife Bank................2016
Remove and Install Crop Diverter................2018
Replace Left-Hand Chopper Rotor Bearing................2021
Replace Right-Hand Chopper Rotor Bearing................2025
Remove Straw Chopper Drive Jackshaft—Style A................2027
Install Straw Chopper Drive Jackshaft—Style A................2031
Remove and Install Straw Chopper Drive Jackshaft—Style B................2035
Powered Tailboard—Exploded View................2043
Remove and Install Powered Tailboard Blades................2045
Remove Straw Spreader................2047
Disassemble and Assemble Straw Spreader................2051
Install Straw Spreader................2055
Group 20: Conveyor Augers, Cleaning Fan and Chaffer and Sieve Frame................1788
Other Material................2399
Specifications................2400
Remove And Install Conveyor Auger Drive Shaft................2062
Remove And Install Conveyor Augers................2067
Remove and Install Conveyor Auger Trough................2070
Remove And Install Conveyor Auger Slip Clutch................2073
Remove and Install Conveyor Auger Bulkhead................2075
Remove And Install Cleaning Fan Sheave And Bearing................2077
Fan Drive Speed Control................2084
Remove Cleaning Fan Drive................2086
Disassemble and Assemble Cleaning Fan Drive Jackshaft................2090
Install Cleaning Fan Drive................2091
Adjust Fan Speed Actuator................2095
Remove And Install Cleaning Fan................2096
Remove And Install Cleaning Fan Blade Inserts................2103
Remove And Install Chaffer/Sieve Frame Clevis—Self-Leveling Shoe................2106
Remove And Install Chaffer................2108
Remove And Install Chaffer With Remote Shoe................2113
Remove And Install Chaffer/Sieve—Self-leveling Shoe................2116
Remove And Install Sieve................2129
Remove And Install Sieve With Remote Shoe................2132
Remove And Install Chaffer/Sieve Rear Channel Assembly—Self-Leveling Shoe................2134
Remove And Install Remote Shoe Actuator Motor................2138
Remove And Install Remote Shoe Actuator Motor—Self-Leveling Shoe................2140
Remove And Install Chaffer/Sieve Tilt Actuator Motor—Self-Leveling Shoe................2142
Remove And Install Front Chaffer Element................2144
Remove And Install Front Chaffer Element—With Chaffer Extension................2146
Remove And Install Chaffer Frame—Without Self-Leveling Shoe................2149
Remove And Install Chaffer Frame—With Self-Leveling Shoe................2152
Remove And Install Sieve Frame—Without Self-Leveling Shoe................2155
Remove And Install Sieve Frame—With Self-Leveling Shoe................2157
Remove And Install Shake Pan................2160
Remove And Install Shoe Pitman Arms................2164
Group 25: Tailings Elevator And Augers................1789
Specifications................2400
Remove and Install Tailings Paddle Chain................2172
Remove and Install Tailings Paddle................2174
Remove Lower Tailings Auger................2175
Install Lower Tailings Auger................2179
Remove Upper Tailings Auger................2183
Install Upper Tailings Auger................2186
Remove Tailings Elevator................2188
Install Tailings Elevator................2197
Group 30: Primary Countershaft Gear Case................1789
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
Remove and Install Primary Countershaft Gear Case................2210
Disassemble and Assemble Primary Countershaft Gear Case................2212
Group 35: Header Electromagnetic Clutch................1789
Specifications................2400
Remove Header Electromagnetic Clutch................2224
Header Electromagnetic Clutch—Exploded View................2226
Install Header Electromagnetic Clutch................2227
Section 130: Grain Tank And Unloading System Repair................2230
Group 05: Grain Tank Cross Augers................2230
Remove Grain Tank Cross Augers (Regular Unload Rate)................2236
Install Grain Tank Cross Augers (Regular Unload Rate)................2240
Remove Grain Tank Cross Augers (High Unload Rate)................2244
Install Grain Tank Cross Augers (High Unload Rate)................2248
Group 10: Unloading Auger System Drives................2230
Specifications................2400
Remove and Install Unloading Auger Drive Belt................2254
Remove and Install Unloading Auger Drive Countershaft................2255
Group 15: Vertical Unloading Auger And Lower Gear Case................2230
Essential or Recommended Tools................2396
Specifications................2400
Remove Vertical Auger Lower Gear Case and Vertical Auger................2261
Disassemble and Assemble Vertical Auger Lower Gear Case................2265
Install Vertical Auger and Vertical Auger Lower Gear Case................2274
Group 20: Horizontal Unloading Auger And Gear Case................2230
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
Inspection of Horizontal Unloading Auger................2283
Horizontal Unloading Auger—Regular Unload Rate................2284
Horizontal Unloading Auger—High Unload Rate................2286
Remove and Install Unloading Auger Grain Saver Door................2288
Remove Horizontal Auger................2289
Install Horizontal Auger................2291
Folding Horizontal Auger Housing—Exploded View................2294
Folding Horizontal Auger—Exploded View................2296
Folding Horizontal Auger Pivot—Exploded View................2298
Remove and Install Folding Auger Actuator................2300
Remove and Install Outer Folding Auger Assembly................2301
Remove and Install Folding Auger Rings................2303
Remove Rear Horizontal Folding Auger................2304
Remove Front Horizontal Folding Auger................2305
Install Front Horizontal Folding Auger................2307
Install Rear Horizontal Folding Auger................2310
Remove Horizontal Auger Gear Case................2311
Disassemble And Assemble Horizontal Unloading Auger Gear Case................2313
Install Horizontal Auger Gear Case................2318
Remove Horizontal Unloading Auger Tube................2319
Install Horizontal Unloading Auger Tube................2320
Unloading Auger Elbow—Exploded View................2321
Remove Horizontal Auger Elbow................2323
Install Horizontal Auger Elbow................2329
Remove Unloading Auger Charge Housing................2334
Install Unloading Auger Charge Housing................2338
Group 25: Clean Grain Elevator................2231
Other Material................2399
Specifications................2400
Adjust Clean Grain Elevator Chain................2344
Remove and Install Clean Grain Paddle Chain................2346
Remove and Install Clean Grain Paddle................2348
Remove Clean Grain Elevator................2349
Install Clean Grain Elevator................2357
Remove and Install Clean Grain Elevator Gear Case................2364
Disassemble and Assemble Clean Grain Elevator Gear Case................2366
Remove and Install Clean Grain Loading Auger................2373
Replace Clean Grain Loading Auger Bearing................2375
Remove and Install Lower Clean Grain Auger................2376
Group 30: Grain Tank And Extensions................2231
Grain Tank................2386
Grain Tank Extensions................2389
Section 140: Engine Gear Case And Control Valve Repair................2392
Group 05: Engine Gear Case And Valve................2392
Essential or Recommended Tools................2396
Other Material................2399
Specifications................2400
General Information................2402
Remove and Install Engine Gear Case................2403
Engine Gear Case Specifications................2414
Remove and Install Rotor Variable Drive................2416
Disassemble and Assemble Rotor Variable Drive................2420
Remove and Install Rotor Variable Drive Shaft................2431
Remove and Install Transfer Gear Case................2433
Disassemble and Assemble Transfer Gear Case................2438
Disassemble and Assemble Separator Drive Wet Clutch................2442
Disassemble and Assemble Hydrostatic Gear Set................2454
Set Gear Position................2456
Preload Bearings................2469
Disassemble and Assemble Straw Chopper/Unloading System................2462
Set Separator Gear Position................2467
Preload Bearings................2469
Disassemble and Assemble Separator Drive................2471
Preload Separator Drive Bearings................2474
Set Separator Drive Gear Backlash................2476
Disassemble and Assemble Hydrostatic Pump Drive................2477
Preload Hydrostatic Pump Drive Bearings................2479
Set Hydrostatic Pump Drive Gear Backlash................2480
Disassemble and Assemble Oil Screen................2481
Disassemble and Assemble Oil Trough................2482
Disassemble and Assemble Dipstick Tube................2484
Remove and Install Filter................2485
Remove and Install Pressure Regulating Valve................2486
Disassemble and Assemble Pressure Regulating Valve................2488
Section 199: Dealer Fabricated Tools................2495
Group 05: Dealer Fabricated Tools................2495
DFRW20—Compressor Holding Fixture................2497
DFHXT1—Split Ring Tool................2498
DFHXT3—Swash Plate Holding Tool................2499
DFHXT4—Split Ring Tool................2501
DFHXT5—Shrink Ring Installation Tool................2502
John Deere Combines 9570 STS, 9670 STS, 9770 STS, 9870 STS Repair Service Manual (TM101919)