Complete service repair manual for John Deere Combines 9560 STS, 9660 STS, 9760 STS, 9860 STS (North American), with technical information to maintain, repair, and service like professional mechanics. John Deere Combines 9560 STS, 9660 STS, 9760 STS, 9860 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.

TM2181 English - 9560 STS, 9660 STS, 9760 STS and 9860 STS Combine Repair.pdf
tm9041 Russian - Peмoнт кoмбaйнoв 9560 STS, 9660 STS, 9760 STS и 9860 STS
tm9141 French - Moissonneuses- batteuses 9560 STS, 9660 STS, 9760 STS et 9860 STSRéparation

Total Pages: 2,219 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English Russian French

MAIN SECTIONS
 Foreword
   General
      Safety
      Specifications
      Tune-Up and Adjustment
      Fuels and Lubricants
   Engine
      Remove and Install Engine
      Cooling System
      Lower Engine Repair
   Fuel and Air Repair
      Air Intake System
      Diesel Fuel System
   Electrical System
      Batteries
      Harness and Connector Repair
      Wire Harness Routing
      Fuses, Circuit Breakers and Relays
      Lighting
      Operators Station
      Sensors and Switches
      Wiper
      Alternator
      Starting Motor
      Electrical Engine Control
      GREENSTAR Components
   Power Train Repair
      Transmission and Differential
      Single Reduction Final Drive-Heavy Duty
      Hydrostatic System
      Cam Lobe Motor
      Tires and Wheels
   Power Steering and Brakes
      Steering
      Brakes
   Hydraulic Repair
      Hydraulic Reservoir
      Hydraulic Pumps
      Hydraulic Valves
      Hydraulic Valve Stack (S.N. -715300)
      Hydraulic Valve Stack (S.N. 715301-)
      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
      CONTOUR MASTER Tilt Cylinder
      CONTOUR MASTER Tilt Frame
   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

tm2181 - 9560 STS™, 9660 STS™, 9760 STS™ and 9860 STS™ Combine Repair

Table of Contents

Foreword

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Handling Batteries Safely

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Service Accumulator Systems Safely

Wait Before Opening High-Pressure Fuel System

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Construct Dealer-Made Tools Safely

Use Proper Tools

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Use Adequate Service Facilities

Live With Safety

Group 10: Specifications

Ground Speeds (Fast Idle) Two Speed Four Wheel Drive

Turning Radius

Operating Speeds—9560 STS

Specifications—9560 STS Combine

Dimensions—9560 STS Combine

Dimension Reference Points—9560 STS Combine

Operating Speeds—9660 STS, 9760 STS Combines

Specifications—9660 STS Combine

Specifications—9760 STS Combine

Dimensions—9660 STS, 9760 STS Combines

Dimension Reference Points—9660 STS, 9760 STS Combines

Operating Speeds—9860 STS Combine

Specifications—9860 STS Combine (S.N. —715700)

Specifications—9860 STS Combine (S.N. 715701—)

Dimensions—9860 STS Combine

Dimension Reference Points—9860 STS Combine

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Sealants and Adhesives Cross-Reference Chart

Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Face Seal Fitting Torque Chart—Standard Pressure Applications

Metric Face Seal Fitting Torque Chart—High Pressure Applications

SAE Face Seal Fitting Torque Chart—Standard Pressure Applications

SAE Face Seal 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

External Hexagon Port Plug Torque Chart

Prevent Hydraulic System Contamination

Check Oil Lines and Fittings

Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems

Group 15: Tune-Up and Adjustment

Tune-Up and Adjustment

Care and Maintenance of Belts

Defective Belts

Group 20: Fuels and Lubricants

Handle Fuel Safely—Avoid Fires

Handling and Storing Diesel Fuel

Diesel Fuel

BioDiesel Fuel

Lubricity of Diesel Fuel

Testing Diesel Fuel

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Operating in Warm Temperature Climates

Supplemental Coolant Additives

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

Testing Diesel Engine Coolant

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

Diesel Engine Oil — Tier 2 and Stage II

Oilscan™ and CoolScan™

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

Transmission, Final Drives, Loading Auger, Primary Countershaft and Two-Speed Separator Drive Gear Cases

Grease

Brake Fluid

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Section 20: Engine

Group 05: Remove and Install Engine

Essential or Recommended Tools

Specifications

John Deere Engine Repair

Remove Engine—6.8 L

Install Engine—6.8 L

Remove Engine—8.1 L

Install Engine—8.1 L

Remove Engine—9.0 L

Install Engine—9.0 L

Remove Engine—12.5 L

Install Engine—12.5 L

Group 10: Cooling System

Essential or Recommended Tools

Specifications

John Deere Engine Repair

Rotary Screen Drive

Rotary Screen Idler Arm and Sheaves

Remove and Install Upper and Lower Air Scoops

Remove and Install Rotary Screen

Adjusting Rotary Screen Knife Comb

Remove Radiator—6.8 L Engine

Install Radiator—6.8 L Engine

Remove Radiator—8.1 L Engine

Install Radiator—8.1 L Engine

Remove Radiator—9.0 L Engine

Install Radiator—9.0 L Engine

Remove Radiator—12.5 L Engine

Install Radiator—12.5 L Engine

Test Radiator

Test Radiator Cap

Replace Thermostats

Repair or Replace Water Pump

Group 15: Lower Engine Repair

Remove and Install Engine Oil Pan Access Sheet

Section 30: Fuel and Air Repair

Group 05: Air Intake System

Other Material

Specifications

John Deere Engine Repair

Remove and Install Turbocharger—8.1 L Engine

Remove and Install Turbocharger—6.8 L and 9.0 L Engine

Remove and Install Turbocharger—12.5 L Engine

Turbocharger Repair

Remove and Install Charge Air Cooler—8.1 L Engine

Remove and Install Charge Air Cooler—6.8 L and 9.0 L Engine

Remove and Install Charge Air Cooler—12.5 L Engine

Cleaning the Charge Air Cooler

Group 10: Diesel Fuel System

Other Material

Specifications

Bleeding Fuel System 8.1 L 9660 (S.N. —705934), 9760 (S.N. —705758)

Bleeding Fuel System 8.1 L Dual Filter System 9660 (S.N. 705935—), 9760 (S.N. 705759—)

Bleed Fuel System—12.5 L Engine

Remove and Install Fuel Return Line Regulator 9560 (S.N. —710250), 9660 (S.N. —710500) 9760 (S.N. —710600), 9860 (S.N. —710700)

Remove and Install Fuel Tank

Remove and Install Fuel Tank Shut-Off Valve and Drain Valve

Remove and Install Fuel Tank Strainer and Breather

Replace Cold Weather Starting Aid Can

Remove and Install Cold Weather Starting Aid

Section 40: Electrical System

Group 05: Batteries

Prevent Battery Explosions

Handling Batteries Safely

Prevent Damage to Electrical Systems

Checking Electrolyte Specific Gravity

Battery Replacement

Remove and Install Batteries

Connecting Booster Batteries

Charging Batteries

Connecting Battery Cables

Group 10: Harness and Connector Repair

Essential or Recommended Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Electrical System Visual Inspection

Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer Controlled Systems

Electrical Connector / Wiring Harness Handling and Repair

Repair Procedure R-A

Repair Procedure R-B

Repair Procedure R-C

Repair Procedure R-D

Repair Procedure R-E

Repair Procedure R-F

Repair Procedure R-G

Repair Procedure R-I

Repair Procedure R-J

Repair Procedure R-K

Repair Procedure R-M

Repair Procedure R-N

Repair Procedure R-AE

Group 15: Wire Harness Routing

Replace Harness

Cab Main Wiring Harness (S.N. —715300)

Cab Main Wiring Harness (S.N. 715301—)

Auxiliary Cab Main AUTOTRAC Wiring Harness (S.N. —715300)

Auxiliary Cab Main AutoTrac Wiring Harness (S.N. 715301—)

Left-Hand Main Wiring Harness

Left-Hand Main Wiring Harness (Tier III Cooling Package)

Right-Hand Main Wiring Harness

Right-Hand Main Wiring Harness (Tier III Cooling Package)

Engine Wiring Harness

Engine Wiring Harness (Tier III Cooling Package)

Group 20: Fuses, Circuit Breakers and Relays

Specifications

Basic Operation

Power Distribution Board System Basic Description

Circuit Board Replacement

Relays

Power Distribution Board Relay Identification

Engine Compartment Relay Panel Fuse Identification

Engine Compartment Relay Panel Identification

Group 25: Lighting

Safety Rules When Replacing Halogen Bulbs

Bulb Part Numbers

Cab Head Light Bulb Replacement and Adjustment (S.N. —715300)

Cab Head Light Bulb Replacement and Adjustment (S.N. 715301—)

Remove and Install High Intensity Discharge (HID-Xenon) Lights (Optional) (S.N. —715300)

Remove and Install High Intensity Discharge (HID-Xenon) Lights (Optional) (S.N. 715301—)

Remove and Install High Intensity Discharge (HID-Xenon) Ballasts (S.N. 715301—)

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

Side Finder (Optional) Light Bulb Replacement

Front Turn Signal, Tail and Side Light Bulb Replacement

Harzard/Warning Light Bulb Replacement

Cleaning Shoe Light Bulb Replacement

Turn Signal Light Bulb Replacement

Dome and Console Light Bulb Replacement

CommandTouch Cornerpost Monitor Light Bulb Replacement

Warning Display Panel Light Bulb Replacement

Group 30: Operators Station

Other Material

Specifications

Instruments and Controls Identification

Overhead Warning Display Panel

Remove and Install Overhead Warning Display Panel

Replace Overhead Warning Display Panel Circuit Board

Remove and Install Light Panel Dimmer Switch

Remove and Install Overhead Display Rocker Switches

Remove and Install ClimaTrak Automatic Air Conditioning/Heater Temperature Control Switch and Fan Switch

Remove and Install Radio

Remove and Install Radio Speaker (S.N. —715300)

Remove and Install Radio Speaker (S.N. 715301—)

Remove and Install Radio Antenna (S.N. —715300)

Remove and Install Radio Antenna (S.N. 715301—)

Replace Cornerpost Main Circuit Board

Remove Header Control Module

Remove Automatic Combine Adjustment (ACA) Display

Remove Performance Monitor and Digital Tachometer Module

CommandTouch Console Controls

Remove and Install CommandTouch Console

Remove and Install Header and Separator Engage Switches

Remove and Install Dial-A-Speed and Active Header Control Switches

Remove and Install Backlight Bulbs for Dial-A-Speed and Active Header Control Switches

Remove and Install CommandTouch Console Membrane Switches

Remove and Install CommandTouch Console Circuit Board

Replace Neutral Safety Switch

Replace Mini Harness

Remove and Install Multi-Function Handle

Remove and Install Start Switch

Remove and Install Starting Aid Switch

Remove and Install Turn Signal/Side Finder Light Switch

Remove and Install Horn Switch

Remove and Install Remote Mirrors (Optional)

Remove and Install Remote Mirror Switch (S.N. —715300) (Optional)

Remove and Install Remote Mirror Switch (S.N. 715301—) (Optional)

Group 35: Sensors and Switches

Essential or Recommended Tools

Other Material

Specifications

Shaft Speed Sensor Locations

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 Tailings Sensor

Remove and Install (Shoe/Separator) VisionTrak VisionTrak is a trademark of Deere & Company Sensors

Remove and Install Concave Position Sensor

Remove and Install Header Height and Lateral Tilt Control Sensors

Remove and Install Multi-Function Handle Feed Rate Sensor

Remove and Install Hydraulic Reservoir Temperature Sensor

Remove and Install Hydraulic Reservoir Temperature Sensor (Tier III Cooling Package)

Remove and Install Coolant Temperature Sensor

Remove and Install Coolant Temperature Sensor (Tier III Cooling Package)

Remove and Install Fuel Level Sensor

Remove and Install Park Brake Switch

Remove and Install Air Filter Restriction Switch

Remove and Install Air Filter Restriction Switch (Tier III Cooling Package)

Remove and Install Fuel Pressure Switch

Remove and Install Engine Gear Case Temperature and Pressure Switches

Remove and Install Hydro Charge Pressure Switch

Remove and Install Engine Oil Pressure Switch

Remove and Install Compressor Inlet Temperature Sensor—9.0 L

Remove and Install Camshaft Position Sensor—9.0 L

Remove and Install Crankshaft Position Sensor—9.0 L

Remove and Install Exhaust Gas Recirculation (EGR) Exhaust Gas Temperature, Fresh Air Temperature and Exhaust Manifold Pressure Sensors—9.0 L

Remove and Install Intake Manifold Pressure and Exhaust Gas Recirculation (EGR) Mixed Gas Temperature Sensor—9.0 L

Remove and Install Turbocharger Speed Sensor—9.0 L

Remove and Install Fuel Rail Pressure Sensor—9.0 L

Remove and Install Switches in the Ground Level Switch Bank

Remove and Install Back-Up Alarm Switch

Back-Up Alarm (S.N. —715300)

Back-Up Alarm—9860 (S.N. 715301—)

Back-Up Alarm—9560, 9660, 9760 (S.N. 715301—)

Group 40: Wiper

Specifications

Remove and Install Wiper Motor

Adjust Windshield Wiper

Remove and Install Windshield Washer (S.N. —715300)

Remove and Install Windshield Washer (S.N. 715301—)

Group 45: Alternator

Essential or Recommended Tools

Specifications

John Deere Engine Accessories—Alternator Repair—Use CTM77

Remove and Install Alternator and Alternator Belt

Remove and Install Voltage Regulator (185 Amp Leece-Neville)

Remove and Install Alternator Pulley (200 Amp Bosch)

Group 50: Starting Motor

Essential or Recommended Tools

Specifications

John Deere Starting Motor Repair—Use CTM77

Remove and Install Starting Motor

Group 55: Electrical Engine Control

Electronic Governor and Speed Controller Repair

Group 60: GREENSTAR Components

Specifications

Other Material

Remove and Install GREENSTAR Mass-Flow Sensor

Remove and Install GREENSTAR Moisture Sensor

Disassemble and Assemble GREENSTAR Moisture Sensor

Remove and Install GREENSTAR Moisture Sensor Actuator

Remove and Install GREENSTAR Moisture Sensor Circuit Board

Remove and Replace GREENSTAR Moisture Sensor Lower Cell Assembly

Disassemble and Assemble Position Receiver

Remove and Install Position Receiver

Section 50: Power Train Repair

Group 05: Transmission and Differential

Other Material

Specifications

Remove and Repair Shifter Forks and Shifter Cam

Install Shifter Forks and Shifter Cam

Remove and Install Transmission Lube Pump

Remove and Install Suction Screen

Remove Transmission

Transmission Components

Transmission Recondition

Disassemble and Repair Transmission

Assemble Transmission

Install Transmission

Remove and Install Gearshift Lever and Linkage

Adjust Gearshift Linkage

Group 10: Single Reduction Final Drive—Heavy Duty

Essential Tools or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive

Disassemble and Assemble Final Drive

Adjust Spindle Bearing

Group 15: Hydrostatic System

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Serial Number Plate

Clean Hydrostatic Motor and Pump

Flushing the Hydrostatic System

Remove and Install Hydrostatic Motor

Disassemble Hydrostatic Motor

Inspect Parts

Lack of Lubrication

Abrasive Contamination

Cavitation

Over Speeding

Inspect Shaft Seal

Inspect Thrust Plate

Inspect Fixed Swashplate

Inspect Piston Slipper

Inspect Piston Retainer

Inspect Cylinder Block

Inspect Bearing Plate

Inspect Valve Plate

Inspect Bearing and Race

Inspect Servo Piston

Inspect Drive Shaft

Replace Cylinder Block Spring

Assemble Motor

Remove and Install Motor Valve Block (Manifold)

Repair Motor Valve Block

Remove Hydrostatic Pump

Disassemble Hydrostatic Drive Pump

Assemble Hydrostatic Drive Pump

Replace High-Pressure Line Center Pivot O-Rings

Disassemble and Assemble End Cover

Repair Displacement Control Valve

Disassemble and Assemble DisplacementControl Valve with Feed Rate (Optional)

Electronic Proportional Displacement Control Valve Neutral Adjustment

Install Hydrostatic Pump

Remove and Install Charge Pump

Repair Charge Pump

Remove and Install Control Cable

Adjust Hydrostatic Neutral Linkage

Adjust Mechanical Displacement Control Valve Neutral

Start-Up Procedure After Hydrostatic System Repair

Group 20: Cam Lobe Motor

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Flushing Cam Lobe Motors

Remove Cam Lobe Motor

Install Cam Lobe Motor

Remove and Install Cam Lobe Motor Control Valve

Disassemble and Assemble Cam Lobe Motor Control Valve

Remove and Install Steering Yoke

Disassemble and Assemble Pivot Pins, Bushings, and Seals

Remove and Install Solenoid Valve and Valve Block

Remove and Install Displacement Control Valve

Remove and Install Cam and Piston Carrier

Remove and Install Stack Valve Seals

Remove and Install Axle Bearings and Seals—Style A

Remove and Install Axle Bearings and Seals—Style B

Group 25: Tires and Wheels

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Service Tires Safely

Care and Service of Tires

Using Liquid Weight

Jacking Locations

Remove and Install Tire

Drive Wheel Bolt Torque

Dual Wheels Bolt Torque

Rear Wheel Bolt Torque

Install Axle Extension Tubes

Install Dual Wheels and Truss Rod

Section 60: Power Steering and Brakes

Group 05: Steering

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Steering Pump Repair

Remove Steering Valve

Steering Valve

Disassemble Steering Valve

Assemble Steering Valve

Install Steering Valve

Electro-Hydraulic Steering Valve and Flowmeter—Exploded View

Remove and Install Flow Meter

AUTOTRAC Assisted Steering Flowmeter—Exploded View

Steering Column Components

Disassemble And Assemble Steering Column

Replace Telescoping Shaft Bearings

Remove and Install Steering Cylinder

Disassemble And Assemble Steering Cylinder

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

Group 10: Brakes

Service Equipment and Tools

Other Material

Specifications

Deglazing Brake Linings

Remove Brake Drum

Remove Brake Shoe

Repair Brakes

Assemble Brakes

Install Brake Drum

Remove and Install Master Cylinder

Disassemble and Assemble Master Cylinder (Double Bleed Screw)

Brake Fluid Reservoir

Adjusting Master Cylinder

Bleeding Brake System—Double Bleed Screw

Remove and Install Slave Cylinders

Disassemble and Assemble Slave Cylinder

Disassemble and Assemble Brake Pedals

Disassemble and Assemble Parking Brake Pedal

Adjust Park Brake Pedal

Section 70: Hydraulic Repair

Group 05: Hydraulic Reservoir

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Reservoir (S.N. —715300)

Remove and Install Reservoir (S.N. 715301—)

Flushing the Hydraulic System

Flushing the Reel/Belt Pickup Drive System

Start-Up Procedure After Hydrostatic System Repair

Group 10: Hydraulic Pumps

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove Triple Main Hydraulic Pump

Marking Triple Main Hydraulic Pump

Disassembling Triple Main Hydraulic Pump

Replace Seal

Triple Main Hydraulic Pump—Exploded View

Assembling Triple Main Hydraulic Pump

Install Triple Main Hydraulic Pump

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 Straw Spreader Pump

Install Straw Spreader Pump

Disassemble Reel/Belt Pickup Straw Spreader Pump

Assemble Reel/Belt Pickup and Straw Spreader Pump

Group 15: Hydraulic Valves

Service Equipment and Tools

Specifications

Electro-Hydraulic Feeder House Reverser Valve—General Information

Electro-Hydraulic Feeder House Reverser Valve and Hoses—Exploded View

Electro-Hydraulic Feeder House Reverser Valve—Exploded View

Remove Straw Spreader Flow Control Valve

Disassemble and Assemble Straw Spreader Flow Control Valve

Install Straw Spreader Flow Control Valve

Remove Reel/Belt Speed Flow Control Valve

Repair Reel/Belt Speed Flow Control Valve

Install Reel/Belt Speed Flow Control Valve

Remove and Install Header Height Control Valve

Remove and Install Accumulator Shut-off Valve

Feeder House Multi-Coupler Valve Identification

Disassemble, Inspect and Assemble Feeder House Multi-Coupler

Group 16: Hydraulic Valve Stack (S.N. —715300)

Service Equipment and Tools

Specifications

Remove and Install Hydraulic Valve Stack

Disassemble and Assemble Hydraulic Valve Stack

Solenoid Control Relief Valve Module

Two-Way Reel Lift and Variable Speed Feeder House Valve Module

Threshing Speed Valve Module

Auger Swing Valve Module

Reel Fore/Aft Valve Module

CONTOUR MASTER (Header Tilt) Valve Module

Hydraulic Solenoid Control Valve Leakage Repair

Replacing Pilot Solenoid Assemblies

Replacing Pilot Sleeve O-Rings

Group 17: Hydraulic Valve Stack (S.N. 715301—)

Service Equipment and Tools

Specifications

Valve Stack Identification

Remove and Install Hydraulic Valve Stack (HIC)

Disassemble and Assemble Hydraulic Valve Stack (HIC)

Group 20: Hydraulic Cylinders

Specifications

Remove and Install Header Lift Cylinder

Disassemble and Assemble Header Lift 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

Group 25: Motors

Remove and Install Straw Spreader Motor

Remove and Install Wide Spread Tailboard Motors

Group 30: Accumulator

Essential or Recommended Tools

Accumulator (General Information)

Checking Header Float System Accumulator

Accumulator Precharge Pressure

Section 80: Separator Shell

Group 05: Gull Wing Doors

Other Material

Specifications

Remove and Install Gull Wing Doors

Remove and Install Rear Wall Panel

Remove and Install Rear Access Door

Composite Panel Repair

Align Gull Wing Doors

Remove and Install Engine Platform Ladder

Section 90: Operator Station Repair

Group 05: Air Conditioning System (R134a)

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Discharge and Recovery of Air Conditioning Refrigerant

Remove and Install Compressor

Test Volumetric Efficiency

Leak Testing Air Conditioning System With Dye

Test Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Disassemble, Inspect, and Assemble Compressor

Remove and Install Compressor Relief Valve

System Information

Flush Air Conditioning System

Purge Air Conditioning System

Evacuate Air Conditioning System

Compressor Oil Information

Determine Correct Oil Charge

Check Refrigerant Oil Charge

Charge Air Conditioning System

Group 10: System Components

Essential or Recommended Tools

Other Material

Specifications

Air Conditioning System With Precleaner (General Information)

Remove and Install Receiver/Dryer

Remove and Install Blower Motor—Style A

Remove and Install Blower Motor—Style B

Remove and Install Recirculator Fan Motor Driver—Style A

Remove and Install Recirculator Fan Motor Driver—Style B

Remove and Install Recirculator Motor—Style A

Remove and Install Recirculator Motor—Style B

Replace Heater Control Valve—Style A

Remove and Install Temperature Control Door Actuator—Style B

Remove and Install Heater Core—Style B

Remove Condenser

Remove Condenser—Tier III Cooling Package

Repair Condenser

Install Condenser

Install Condenser—Tier III Cooling Package

Replace Evaporator—Style A

Replace Evaporator—Style B

Replace Expansion Valve—Style A

Replace Expansion Valve—Style B

Remove and Install Evaporator Temperature Sensor—Style A

Remove and Install Evaporator Temperature Sensor—Style B

Replace Low Pressure Switch

Replace High Pressure Switch

Replace Air Temperature Sensors

Group 15: Cab

Specifications

Remove and Install Cab Windshield—Style A

Remove and Install Cab Windshield—Style B

Remove Cab

Install Cab

Replace Rear Window

Remove and Install Cab Roof—Style A

Remove and Install Cab Outer Roof—Style B

Remove and Install Cab Inner Roof—Style B

Remove and Install Cab Headliner—Style B

Remove and Install Operator's Seat

Remove and Install Armrest Control Pivot—Style A

Remove and Install Armrest Control Pivot—Style B

Disassemble and Assemble Armrest Control Pivot—Style A

Remove and Install Operator Presence Switch

Operator Seat—Exploded View

Operator Seat Air Suspension Assembly—Exploded View

Disassemble and Assemble Operator Seat Air Suspension Assembly

Remove and Install Cab Door

Disassemble and Assemble Cab Door

Cab Door Latch Striker

Section 110: Feeder House Repair

Group 05: Conveyor

Other Material

Specifications

Remove and Install Feeder House

Feeder House Conveyor Chain—Adjust

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

Remove And Install Sub-Floor Assembly

Remove and Install Front Wear Plates

Single Point Latching Level Land—Exploded View

Remove and Install Feed Plate

Adjust Feed Plate Assembly

Feed Plate Support—Exploded View

Group 10: Top Shaft and Slip Clutch

Essential or Recommended Tools

Other Material

Specifications

Remove Top Shaft Slip Clutch (9660, 9760 and 9860)

Disassemble and Assemble Top Shaft Slip Clutch

Install Top Shaft Slip Clutch (9660 STS, 9760 STS and 9860 STS)

Remove and Install Top Shaft Slip Clutch (9560 STS)

Remove and Install Top Shaft Supports

Disassemble and Assemble Top Shaft

Group 15: Feeder House Drives and Reverser Gear Case

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Variable Drive Countershaft

Disassemble and Assemble Upper Variable Drive Countershaft

Disassemble and Assemble Standard Capacity Fixed Speed Countershaft

Backshaft Speed Sensor

Remove, Repair and Install Variable Drive Sheaves and Cams—Style A

Repair Variable Drive Sheaves and Cams—Style B

Remove and Install Variable Drive Sheaves and Cams—Style B

Remove and Install Fixed Drive Sheave

Remove and Install Reverser Gear Case

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

Remove and Install Oil Cooler

Disassemble and Assemble Fixed Speed Drive Tightener

Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides

Feeder House Variable Speed Belt—Adjustment

Replace Variable Speed Feeder House Belt

Replace and Adjust Fixed Speed Feeder House Belt

Group 20: CONTOUR MASTER Tilt Cylinder

CONTOUR MASTERTilt Cylinder Hoses and Fittings

Tilt Cylinder

Remove and Install CONTOUR MASTER Tilt Cylinder

Group 25: CONTOUR MASTER Tilt Frame

Other Material

Specifications

Tilt Frame and Beam(S.N. —720100)

Tilt Frame and Beam(S.N. 720101—)

Remove and Install Tilt Frame

Remove and Install Tilt Beam

Adjust Single Point Latching

Lateral Tilt Beam with Single Point Latching—Exploded View (S.N. —715300)

Lateral Tilt Beam with Single Point Latching—Exploded View (S.N. 715301—)

Adjust Fore-Aft Turnbuckles

Remove Fore-Aft Tilt Frame

Install Fore-Aft Tilt Frame

Section 120: Separator

Group 05: Separator Repair

Essential or Recommended Tools

Other Material

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 STS Rotor Front Bearing

Remove and Install Stone Trap Door

Remove and Install STS Rotor

Replace Rear Bulkhead (Rotor Drive Gear Case Support)

Remove and Install STS Rotor Torque Sensing—Driven

Disassemble and Assemble STS Rotor Torque Sensing—Driven

Remove and Install STS Rotor Drive Gear Case

Disassemble and Assemble STS Rotor Drive Gear Case

Remove And Install Discharge Beater Grate Section

Remove And Install Discharge Beater Grate Frame

Remove And Install Discharge Beater

Remove and Install Discharge Beater Drive Hub

Remove and Install Discharge Beater Housing

Remove And Install Separator Grates

Remove and Install Concave Sections

Adjust Concave Level

Remove and Install Concave Adjusting Motor

Remove And Install Concave Adjusting Tube

Remove and Install Front Bulkhead

Remove and Install Center Bulkhead

Repair Separator Rotor Shell

Remove And Install Threshing Elements And Tines

Threshing Element and Separator Tine Location (9560)

Threshing Bar And Separator Tine Location (S.N. —715300)

Threshing Bar And Separator Tine Location (Rice) (S.N. —715300)

Threshing Element and Separator Tine Location (15 Element Configuration)

Threshing Element and Separator Tine Location (24 Element Dense Pack Configuration)

Remove And Replace RIVNUT Threaded Inserts

Remove And Install STS Rotor Feed Flights

Static Balance STS Rotor

Aligning Rotor Drive Bulkhead

Group 10: Separator Drives

Essential or Recommended Tools

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

Remove and Install Primary Drive Shafts

Replace Drive Shaft Carrier Bearing

Group 15: Residue Disposal

Service Equipment and Tools

Other Material

Specifications

Straw Chopper Rotor (Fine Cut)

Straw Chopper Rotor (Extra Fine Cut)

Straw Chopper Housing

Remove Straw Chopper

Remove and Install Chopper Raise/Lower Actuator

Install Straw Chopper

Chopper Blades Replacement and Configuration—9560

Remove and Replace Straw Chopper Blades (Fine Cut)

Remove and Replace Straw Chopper Blades (Extra Fine Cut)

Replace Knife Blades (S.N. —715300)

Replace Knife Blades (S.N. 715301—)

Remove and Install Easy Adjust Knife Bank

Remove and Install Crop Diverter

Replace Left-Hand Chopper Rotor Bearing

Replace Right-Hand Chopper Rotor Bearing

Remove Straw Chopper Drive Jackshaft

Install Straw Chopper Drive Jackshaft

Powered Tailboard—Exploded View

Remove and Install Powered Tailboard Blades

Remove Straw Spreader

Disassemble and Assemble Straw Spreader

Install Straw Spreader

Group 20: Conveyor Augers, Cleaning Fan and Chaffer and Sieve Frame

Other Material

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

Remove And Install Chaffer With Remote Shoe

Remove And Install Sieve

Remove and Install Sieve With Remote Shoe

Remove and Install Remote Shoe Actuator Motor

Remove and Install Front Chaffer Element

Remove and Install Chaffer Frame

Remove and Install Sieve Frame

Remove and Install Shake Pan

Remove and Install Shoe Pitman Arms

Group 25: Tailings Elevator and Augers

Specifications

Remove Lower Tailings Auger

Install Lower Tailings Auger

Remove Upper Tailings Auger

Install Upper Tailings Auger

Remove Tailings Elevator

Install Tailings Elevator

Group 30: Primary Countershaft Gear Case

Essential or Recommended Tools

Other Material

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 Repair

Group 05: Grain Tank Cross Augers

Remove Grain Tank Cross Augers (Regular Unload Rate)

Install Grain Tank Cross Augers (Regular Unload Rate)

Remove Grain Tank Cross Augers (High Unload Rate)

Install Grain Tank Cross Augers (High Unload Rate)

Group 10: Unloading Auger System Drives

Specifications

Remove and Install Unloading Auger Drive Belt

Remove and Install Unloading Auger Drive Countershaft—Style A

Remove and Install Unloading Auger Drive Countershaft—Style B

Group 15: Vertical Unloading Auger and Lower Gear Case

Essential or Recommended Tools

Specifications

Remove Vertical Auger Lower Gear Case and Vertical Auger

Disassemble and Assemble Vertical Auger Lower Gear Case

Install Vertical Auger and Vertical Auger Lower Gear Case

Group 20: Horizontal Unloading Auger and Gear Case

Essential or Recommended Tools

Other Material

Specifications

Inspection of Horizontal Unloading Auger

Horizontal Unloading Auger—Regular Unload Rate

Horizontal Unloading Auger—High Unload Rate

Remove and Install Unloading Auger Grain Saver Door

Remove Horizontal Auger

Install Horizontal Auger

Folding Horizontal Auger Housing—Exploded View

Folding Horizontal Auger—Exploded View

Folding Horizontal Auger Pivot—Exploded View

Remove and Install Folding Auger Actuator

Remove and Install Outer Folding Auger Assembly

Remove and Install Folding Auger Rings

Remove Rear Horizontal Folding Auger

Remove Front Horizontal Folding Auger

Remove Front Horizontal Folding Auger

Install Front Horizontal Folding Auger

Install Rear Horizontal Folding Auger

Remove Horizontal Auger Gear Case

Disassemble And Assemble Horizontal Unloading Auger Gear Case

Install Horizontal Auger Gear Case

Remove Horizontal Unloading Auger Tube

Install Horizontal Unloading Auger Tube

Unloading Auger Elbow—Exploded View

Remove Horizontal Auger Elbow

Install Horizontal Auger Elbow

Remove Unloading Auger Charge Housing

Install Unloading Auger Charge Housing

Group 25: Clean Grain Elevator

Other Material

Specifications

Adjust Clean Grain Elevator Chain

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

Replace Clean Grain Loading Auger Bearing

Remove And Install Lower Clean Grain Auger

Group 30: Grain Tank and Extensions

Grain Tank

Grain Tank Extensions

Section 140: Engine Gear Case and Control Valve Repair

Group 05: Engine Gear Case and Valve

Essential or Recommended Tools

Other Material

Specifications

General Information

Remove and Install Engine Gear Case

Engine Gear Case Specifications

Remove and Install STS Rotor Variable Drive

Disassemble and Assemble STS Rotor Variable Drive

Remove and Install STS Rotor Variable Drive Shaft

Remove and Install Transfer Gear Case

Disassemble and Assemble Transfer Gear Case

Disassemble and Assemble Separator Drive Wet Clutch

Disassemble and Assemble Hydrostatic Gear Set

Set Gear Position

Preload Bearings

Disassemble and Assemble Straw Chopper/Unloading System

Set Separator Gear Position

Preload Bearings

Disassemble and Assemble Separator Drive

Preload Separator Drive Bearings

Set Separator Drive Gear Backlash

Disassemble and Assemble Hydrostatic Pump Drive

Preload Hydrostatic Pump Drive Bearings

Set Hydrostatic Pump Drive Gear Backlash

Disassemble and Assemble Oil Screen

Disassemble and Assemble Oil Trough

Disassemble and Assemble Dipstick Tube

Remove and Install Filter

Remove and Install Pressure Regulating Valve

Disassemble and Assemble Pressure Regulating Valve

Section 199: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFRW20—Compressor Holding Fixture

DFHXT1—Split Ring Tool

John Deere Combines Models 9560 STS, 9660 STS, 9760 STS, 9860 STS Repair Technical Manual (TM2181)