9560STS™, 9660STS™, 9760STS™ and 9860STS™ Combine Repair
REPAIR TECHNICAL MANUAL 9860 STS, 9660 STS, 9760 STS, 9560 STS TM2181 14 APR 15 (ENGLISH)
For complete service information also see: 9560 STS, 9660 STS, 9760 STS and 9860 STS Combines Diagnosis
TM2182
PowerTech 8.1 L Diesel Engines Base Engine
CTM86
Alternators and Starting Motors
CTM77
PowerTech 9.0 L OEM Diesel Engines Base Engine Repair
CTM400
PowerTech 9.0 L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR
CTM385
PowerTech Plus 4.5L and 6.8L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR
CTM320
PowerTech 8.1L Diesel Engines Level 9 Electronic Fuel System With Denso High Pressure Common Rail
CTM255
PowerTech 10.5 L & 12.5 L Diesel Engines, Level 6 Electronic Fuel Systems with Lucas EUIs
CTM188
PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)
CTM104
PowerTech 10.5 L & 12.5 L Diesel Base Engine
CTM100
John Deere Agriculture
TM2181-REPAIR TECHNICAL MANUAL
(g) by Belgreen v2.1
Table of contents FOREWORD Section 10 - GENERAL Group 05 - Safety Group 10 - Specifications Group 15 - Tune-Up and Adjustment Group 20 - Fuels and Lubricants Section 20 - ENGINE Group 05 - Remove and Install Engine Group 10 - Cooling System Group 15 - Lower Engine Repair Section 30 - FUEL AND AIR REPAIR Group 05 - Air Intake System Group 10 - Diesel Fuel System Section 40 - ELECTRICAL SYSTEM Group 05 - Batteries Group 10 - Harness and Connector Repair Group 15 - Wire Harness Routing Group 20 - Fuses, Circuit Breakers and Relays Group 25 - Lighting Group 30 - Operators Station Group 35 - Sensors and Switches Group 40 - Wiper Group 45 - Alternator Group 50 - Starting Motor Group 55 - Electrical Engine Control Group 60 - GREENSTAR Components Section 50 - POWER TRAIN REPAIR Group 05 - Transmission and Differential Group 10 - Single Reduction Final Drive—Heavy Duty Group 15 - Hydrostatic System Group 20 - Cam Lobe Motor Group 25 - Tires and Wheels Section 60 - POWER STEERING AND BRAKES Group 05 - Steering Group 10 - Brakes Section 70 - HYDRAULIC REPAIR Group 05 - Hydraulic Reservoir Group 10 - Hydraulic Pumps Group 15 - Hydraulic Valves Group 16 - Hydraulic Valve Stack (S.N. —715300) Group 17 - Hydraulic Valve Stack (S.N. 715301—) Group 20 - Hydraulic Cylinders Group 25 - Motors Group 30 - Accumulator Section 80 - SEPARATOR SHELL Group 05 - Gull Wing Doors Section 90 - OPERATOR STATION REPAIR Group 05 - Air Conditioning System (R134a) Group 10 - System Components Group 15 - Cab Section 110 - FEEDER HOUSE REPAIR Group 05 - Conveyor <- Go to Global Table of contents
TM2181-REPAIR TECHNICAL MANUAL
TM2181-REPAIR TECHNICAL MANUAL
(g) by Belgreen v2.1
Group 10 - Top Shaft and Slip Clutch Group 15 - Feeder House Drives and Reverser Gear Case Group 20 - CONTOUR MASTER Tilt Cylinder Group 25 - CONTOUR MASTER Tilt Frame Section 120 - SEPARATOR Group 05 - Separator Repair Group 10 - Separator Drives Group 15 - Residue Disposal Group 20 - Conveyor Augers, Cleaning Fan And Chaffer And Sieve Frame Group 25 - Tailings Elevator and Augers Group 30 - Primary Countershaft Gear Case Group 35 - Header Electromagnetic Clutch Section 130 - GRAIN TANK AND UNLOADING SYSTEM REPAIR Group 05 - Grain Tank Cross Augers Group 10 - Unloading Auger System Drives Group 15 - Vertical Unloading Auger and Lower Gear Case Group 20 - Horizontal Unloading Auger and Gear Case Group 25 - Clean Grain Elevator Group 30 - Grain Tank and Extensions Section 140 - ENGINE GEAR CASE AND CONTROL VALVE REPAIR Group 05 - Engine Gear Case and Valve Section 199 - DEALER FABRICATED TOOLS Group 05 - Dealer Fabricated Tools
<- Go to Global Table of contents
TM2181-REPAIR TECHNICAL MANUAL
<- Go to Global Table of contents
TM2181-REPAIR TECHNICAL MANUAL
GENERAL
(g) by Belgreen v2.0
Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
<- Go to Section TOC
Section 10 page 1
TM2181-REPAIR TECHNICAL MANUAL
TM2181-REPAIR TECHNICAL MANUAL
(g) by Belgreen v2.1
Section 10 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 2 Handling Batteries Safely ..................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 4 Prevent Acid Burns ............................................................................................................................... 6 Handle Chemical Products Safely ......................................................................................................... 6 Avoid High-Pressure Fluids ................................................................................................................... 7 Service Accumulator Systems Safely .................................................................................................... 8 Wait Before Opening High-Pressure Fuel System ................................................................................. 8 Park Machine Safely ............................................................................................................................. 8 Support Machine Properly .................................................................................................................... 9 Wear Protective Clothing .................................................................................................................... 10 Work in Clean Area ............................................................................................................................. 10 Service Machines Safely ..................................................................................................................... 11 Work In Ventilated Area ...................................................................................................................... 11 Illuminate Work Area Safely ............................................................................................................... 11 Replace Safety Signs .......................................................................................................................... 12 Use Proper Lifting Equipment ............................................................................................................. 12 Remove Paint Before Welding or Heating ........................................................................................... 13 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 14 Service Tires Safely ............................................................................................................................ 15 Avoid Harmful Asbestos Dust ............................................................................................................. 15 Practice Safe Maintenance ................................................................................................................. 17 Construct Dealer-Made Tools Safely ................................................................................................... 17 Use Proper Tools ................................................................................................................................. 18 Dispose of Waste Properly .................................................................................................................. 18 Use Adequate Service Facilities .......................................................................................................... 19 Live With Safety ................................................................................................................................. 19 Group 10 - Specifications ..................................................................................................................... 21 Ground Speeds (Fast Idle) Two Speed Four Wheel Drive .................................................................... 21 Turning Radius ................................................................................................................................... 21 Operating Speeds—9560 STS ............................................................................................................. 22 Specifications—9560 STS Combine .................................................................................................... 24 Dimensions—9560 STS Combine ........................................................................................................ 26 Dimension Reference Points—9560 STS Combine .............................................................................. 27 Operating Speeds—9660 STS, 9760 STS Combines ........................................................................... 28 Specifications—9660 STS Combine .................................................................................................... 30 Specifications—9760 STS Combine .................................................................................................... 32 Dimensions—9660 STS, 9760 STS Combines ..................................................................................... 34 Dimension Reference Points—9660 STS, 9760 STS Combines ........................................................... 35 Operating Speeds—9860 STS Combine .............................................................................................. 36 Specifications—9860 STS Combine (S.N. —715700) .......................................................................... 38 Specifications—9860 STS Combine (S.N. 715701—) .......................................................................... 40 Dimensions—9860 STS Combine ........................................................................................................ 42 Dimension Reference Points—9860 STS Combine .............................................................................. 43 Metric Bolt and Screw Torque Values ................................................................................................. 44 Unified Inch Bolt and Screw Torque Values ........................................................................................ 45 <- Go to Global Table of contents
TM2181-REPAIR TECHNICAL MANUAL
TM2181-REPAIR TECHNICAL MANUAL
(g) by Belgreen v2.1
Sealants and Adhesives Cross-Reference Chart ................................................................................. 46 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................ 46 Metric Face Seal Fitting Torque Chart—Standard Pressure Applications ............................................ 48 Metric Face Seal Fitting Torque Chart—High Pressure Applications ................................................... 49 SAE Face Seal Fitting Torque Chart—Standard Pressure Applications ................................................ 50 SAE Face Seal Fitting Torque Chart—High Pressure Applications ....................................................... 51 Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications ................................. 51 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications ............................. 53 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications .................................... 54 External Hexagon Port Plug Torque Chart .......................................................................................... 55 Prevent Hydraulic System Contamination .......................................................................................... 55 Check Oil Lines and Fittings ............................................................................................................... 55 Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems ....................................................................................................................................... 56 Group 15 - Tune-Up and Adjustment .................................................................................................. 58 Tune-Up and Adjustment .................................................................................................................... 58 Care and Maintenance of Belts ........................................................................................................... 59 Defective Belts ................................................................................................................................... 60 Group 20 - Fuels and Lubricants ......................................................................................................... 63 Handle Fuel Safely—Avoid Fires ......................................................................................................... 63 Handling and Storing Diesel Fuel ........................................................................................................ 63 Diesel Fuel .......................................................................................................................................... 64 BioDiesel Fuel ..................................................................................................................................... 65 Lubricity of Diesel Fuel ....................................................................................................................... 66 Testing Diesel Fuel ............................................................................................................................. 66 Diesel Engine Coolant (engine with wet sleeve cylinder liners) .......................................................... 67 Operating in Warm Temperature Climates ......................................................................................... 68 Supplemental Coolant Additives ......................................................................................................... 68 Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER ..................................................................................................................................................... 70 Testing Diesel Engine Coolant ............................................................................................................ 71 Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III ............................................................................................................................ 72 Diesel Engine Oil — Tier 2 and Stage II .............................................................................................. 73 Oilscan™ and CoolScan™ ................................................................................................................... 74 Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils ......................... 74 Transmission, Final Drives, Loading Auger, Primary Countershaft and Two-Speed Separator Drive Gear Cases ........................................................................................................................................... 75 Grease ................................................................................................................................................ 77 Brake Fluid ......................................................................................................................................... 77 Lubricant Storage ............................................................................................................................... 78 Alternative and Synthetic Lubricants .................................................................................................. 78 Mixing of Lubricants ........................................................................................................................... 78
<- Go to Global Table of contents
TM2181-REPAIR TECHNICAL MANUAL
Section 10 - GENERAL
Group 05: Safety
Group 05 - Safety Recognize Safety Information
Safety-alert symbol This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.
Understand Signal Words
Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
Handle Fluids Safely—Avoid Fires
<- Go to Section TOC
Section 10 page 1
TM2181-REPAIR TECHNICAL MANUAL
Section 10 - GENERAL
Group 05: Safety
Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously.
Prevent Battery Explosions
Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Handling Batteries Safely
<- Go to Section TOC
Section 10 page 2
TM2181-REPAIR TECHNICAL MANUAL
Section 10 - GENERAL
Group 05: Safety
CAUTION:
Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last.
Caution—Explosive
CAUTION:
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.
<- Go to Section TOC
Section 10 page 3
TM2181-REPAIR TECHNICAL MANUAL