John Deere 9450 9550 9650 Combine Diagnosis and Tests Manual TM1802

9450, 9550 and 9650 Combines

DOWNLOAD DIAGNOSIS AND TESTS MANUAL

Combines models 9450, 9550, 9650 (S.N: 000000-695100)

TM1802 04 AUG 15

For complete service information also see:

9450, 9550, 9650 Combines Repair

PowerTech 8.1 L Diesel Engines Base Engine

Alternators and Starting Motors

OEM Engine Accessories

Cam Lobe Motors

PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic Fuel Systems with Bosch In-Line Pump)

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)

TM1801

CTM86

CTM77

CTM67

CTM19

(ENGLISH)

John Deere Agriculture

CTM134

CTM104

Table of contents

FOREWORD

Section 210 - GENERAL

Group 05 - Safety

Group 10 - Combine and Component Identification

Group 15 - General Specifications

Group 20 - Diagnostic and Testing Procedures

Section 211 - DIAGNOSTIC TROUBLE CODES

Group A00 - A00 - Engine Control Unit Diagnostic Trouble Codes

Group C00 - C00 - Armrest Control Unit Diagnostic Trouble Codes

Group C03 - C03 - Cornerpost Control Unit Diagnostic Trouble Codes

Group E00 - E00 - Tailing Master Sensor Diagnostic Trouble Codes

Group E01 - E01 - Header Control Unit Diagnostic Trouble Codes

Group E02 - E02 - Right Control Unit Diagnostic Trouble Codes

Group AMS - GREENSTAR Display Warning Messages and Fault Codes

Group AMS - GREENSTAR KeyCard and PC Data Storage Card Warning Messages

Group AMS - GREENSTAR Mobile Processor Warning Messages

Group AMS - HARVEST DOC Warning Messages

Group AMS - Moisture Sensor Warning Messages

Group AMS - STARFIRE Receiver Warning Messages

Group AMS - Terrain Compensation Module Fault Codes

Section 212 - OBSERVABLE SYMPTOMS

Group 220 - Engine System

Group 230 - Air Intake and Cooling Systems

Group 240 - Electrical System

Group 250 - Power Train System

Group 255 - Four Wheel Drive System

Group 260 - Brake System

Group 270 - Hydraulic System

Group 275 - Main Gearcase System

Group 280 - Steering System

Group 290 - CLIMATRAK System

Group 300 - Separator System

Section 220 - ENGINE SYSTEM

Group 05 - General Information

Group 10 - Test Procedures and Adjustments

Group 15A - Engine Type Identification

Group 15B - Engine Diagnostics - Type A

Group 15C - Engine Diagnostics - Type B

Group 20 - Component Identification and Location

Section 230 - AIR INTAKE AND COOLING SYSTEMS

Group 05 - General Information

Group 10 - Test Procedures and Adjustments

Group 15A - Engine Type Identification

Group 15B - Air Intake System Diagnostics

Group 15C - Engine Cooling Package Diagnostics - Type A

Group 15D - Engine Cooling Package Diagnostics - Type B

Group 20 - Component Identification and Location

Section 240 - ELECTRICAL SYSTEM

Group 5 - General Information

Group 10 - Diagnostic Trouble Codes

Group 15A - Active Header Height Control System -Height Sensing Diagnostics

Group 15B - Active Header Height Control System - Height Resume Diagnostics

Group 15C - Active Header Height Control System - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Diagnostics

Group 15D - 95 Ampere Alternator / Battery Diagnostics

Group 15E - 185 Ampere Alternator / Battery Diagnostics

Group 15F - Armrest Control Unit Overall Diagnostics

Group 15G - Auxiliary Power Strip Outlet Diagnostics (Power Strip)

Group 15H - CAN Bus Type Identification

Group 15I - CAN Bus Diagnostics - Type A

Group 15J - CAN Bus Diagnostics - Type B

Group 15K - Cleaning Fan Speed Adjust Diagnostics

Group 15L - CLIMATRAKCLIMATRAK is a trademark of Deere & Company Diagnostics

Group 15M - COMFORT COMMANDComfort Command is a trademark of Deere & Company Seat Diagnostics

Group 15N - Concave Clearance Adjust Diagnostics

Group 15O - CONTOUR MASTERContour Master is a trademark of Deere & Company - Automatic Tilt Diagnostics

Group 15P - CONTOUR MASTER Contour Master is a trademark of Deere & Company - Manual Tilt Diagnostics

Group 15Q - Cornerpost Control Unit Overall Diagnostics

Group 15R - Cornerpost - Cleaning Fan Speed Diagnostics

Group 15S - Cornerpost - Concave Clearance Diagnostics

Group 15T - Cornerpost - CONTOUR MASTER Contour Master is a trademark of Deere & Company Position Diagnostics

Group 15U - Cornerpost - Corn Head Deck Plate Spacing Diagnostics

Group 15V - Cornerpost - Cylinder Speed Diagnostics

Group 15W - Cornerpost - Engine Hours Diagnostics

Group 15X - Cornerpost - Engine Speed Type Identification

Group 15Y - Cornerpost - Engine Speed - 6068 Diagnostics

Group 15Z - Cornerpost - Engine Speed - 6081 Diagnostics

Group 15AA - Cornerpost - Engine Temperature Gauge Type Identification

Group 15AB - Cornerpost - Engine Temperature Gauge - 6068 Diagnostics

Group 15AC - Cornerpost - Engine Temperature Gauge - 6081 Diagnostics

Group 15AD - Cornerpost - Feeder House Backshaft Speed Diagnostics

Group 15AE - Cornerpost - Fuel Gauge Diagnostics

Group 15AF - Cornerpost - Ground Speed Diagnostics

Group 15AG - Cornerpost - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Pressure Diagnostics

Group 15AH - Cornerpost - Separator Hours Diagnostics

Group 15AI - Cylinder Speed Adjust Diagnostics

Group 15AJ - Deck Plate Adjustment Diagnostics

Group 15AK - DIAL-A-SPEEDDIAL-A-SPEED is a trademark of Deere & Company Diagnostics

Group 15AL - Draper Speed Adjust Diagnostics

Group 15AM - Electric Fuel Pump Diagnostics

Group 15AN - Engine and Fuel Control Diagnostics - 6068 Engine

Group 15AO - Engine and Fuel Control Diagnostics - 6081L3 Engine

Group 15AP - Engine Compartment Relay Panel Diagnostics

Group 15AQ - Engine Control Unit Overall Diagnostics - 6081L3

Group 15AR - Four Wheel Drive Type Identification

Group 15AS - Four Wheel Drive - Single Speed Diagnostics

Group 15AT - Four Wheel Drive - Two Speed Diagnostics

Group 15AU - GREENSTARGREENSTAR is a trademark of Deere & Company - Display Diagnostics

Group 15AV - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver Type Identification

Group 15AW - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver

Diagnostics - Type A

Group 15AX - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver Diagnostics

- Type B

Group 15AY - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver Diagnostics

- Type C

Group 15AZ - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver Diagnostics

- Type D

Group 15BA - GREENSTARGREENSTAR is a trademark of Deere & Company - KeyCard and PC Data

Storage Card Diagnostics

Group 15BB - GREENSTARGREENSTAR is a trademark of Deere & Company - Mass Flow Sensor Type

Identification

Group 15BC - GREENSTARGREENSTAR is a trademark of Deere & Company - Mass Flow Sensor

Diagnostics - Type A

Group 15BD - GREENSTARGREENSTAR is a trademark of Deere & Company - Mass Flow Sensor

Diagnostics - Type B

Group 15BE - GREENSTARGREENSTAR is a trademark of Deere & Company - Mobile Processor Diagnostics

Group 15BF - GREENSTARGREENSTAR is a trademark of Deere & Company - Moisture Sensor Type

Identification

Group 15BG - GREENSTARGREENSTAR is a trademark of Deere & Company - Moisture Sensor

Diagnostics - Type A

Group 15BH - GREENSTARGREENSTAR is a trademark of Deere & Company - Moisture Sensor

Diagnostics - Type B

Group 15BI - GREENSTARGREENSTAR is a trademark of Deere & Company - Harvest/Yield

Mapping/Monitoring Type Identification

Group 15BJ - GREENSTARGREENSTAR is a trademark of Deere & Company System - HARVEST

DOCHARVEST DOC is a trademark of Deere & Company Diagnostics

Group 15BK - GREENSTARGREENSTAR is a trademark of Deere & Company System - Harvest Monitor Diagnostics

Group BL - GREENSTARGREENSTAR is a trademark of Deere & Company System - Parallel Tracking Diagnostics

Group 15BM - GREENSTARGREENSTAR is a trademark of Deere & Company System - Yield Mapping Diagnostics

Group 15BN - GREENSTARGREENSTAR is a trademark of Deere & Company - System - Yield Monitor System

Group 15BO - Header Control Unit Overall Diagnostics

Group 15BP - Header Engage Diagnostics

Group 15BQ - Header Raise / Lower Diagnostics

Group 15BR - Horn Diagnostics

Group 15BS - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Pressure Adjustment Type Identification

Group 15BT - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Pressure Adjustment Diagnostics - Type A

Group 15BU - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Pressure Adjustment Diagnostics - Type B

Group 15BV - Lighting System - Overall Diagnostics

Group 15BW - Lighting System - Daytime Running Lighting Diagnostics

Group 15BX - Lighting System - Dome Light Diagnostics

Group 15BY - Lighting System Exit Lights Diagnostics

Group 15BZ - Lighting System - Field Lights Type Identification

Group 15CA - Lighting System - Field Light Diagnostics - Type A

Group 15CB - Lighting System - Field Light Diagnostics - Type B

Group 15CC - Lighting System Hazard/Turn Lights Diagnostics

Group 15CD - Lighting System - Marker Lamps Diagnostics

Group 15CE - Lighting System Panel Lamps Diagnostics

Group 15CF - Lighting System Rear Discharge Lamps Diagnostics

Group 15CG - Lighting System - Road Lamps Diagnostics

Group 15CH - Lighting System - Service Lamps - Engine Area Diagnostics

Group 15CI - Lighting System - Service Lamps - Gullwing Doors Diagnostics

Group 15CJ - Lighting System - Service Lamps - Shoe Area Diagnostics

Group 15CK - Lighting System Side Finder Lamps Diagnostics

Group 15CL - Lighting System - Stubble Lights Diagnostics

Group 15CM - Lighting System Unloading Auger Light Diagnostics

Group 15CN - Multifunction Control Handle Diagnostics

Group 15CO - Power Distribution Board 1 - Overall Diagnostics

Group 15CP - Power Distribution Board 1 Control Circuit Power Diagnostics

Group 15CQ - Power Distribution Board 1 - EMIP Power Diagnostics

Group 15CR - Power Distribution Board 1 - Engine Running Power Diagnostics

Group 15CS - Power Distribution Board 1 - Ignition Switch Power Diagnostics

Group 15CT - Power Distribution Board 1 - Light Switch Power Diagnostics

Group 15CU - Power Distribution Board 1 Service Power Diagnostics

Group 15CV - Quick-Stop System Diagnostics

Group 15CW - Radio System Diagnostics

Group 15CX - Reel Fore/Aft Diagnostics

Group 15CY - Reel Fore/Aft Resume Diagnostics

Group 15CZ - Reel Raise/Lower Type Identification

Group 15DA - Reel Raise/Lower Diagnostics - Type A

Group 15DB - Reel Raise/Lower Diagnostics - Type B

Group 15DC - Reel Raise/Lower Diagnostics - Type C

Group 15DD - Reel Raise/Lower Diagnostics - Type D

Group 15DE - Reel Raise/Lower Resume Diagnostics

Group 15DF - Reel/Belt Speed Adjust Diagnostics

Group 15DG - Right Control Unit Overall Diagnostics

Group 15DH - Road/Field System Diagnostics

Group 15DI - Separator Engage Diagnostics

Group 15DJ - Start Aid Diagnostics

Group 15DK - Starting System Diagnostics

Group 15DL - Tailings Monitor Diagnostics

Group 15DM - Unloading Auger Engage Diagnostics

Group 15DN - Unloading Auger Swing Diagnostics

Group 15DO - Variable Speed Feeder House Adjust Type Identification

Group 15DP - Variable Speed Feeder House Adjust Diagnostics - Type A

Group 15DQ - Variable Speed Feeder House Adjust Diagnostics - Type B

Group 15DR - VISIONTRAK VisionTrak is a trademark of Deere & Company Diagnostics

Group 15DS - Warning Display Panel Overall Diagnostics

Group 15DT - Warning Grain Elevator Speed w/ GREENSTARGREENSTAR is a trademark of Deere & Company Diag.

Group 15DU - Warning - Grain Elevator Speed w/o GREENSTARGREENSTAR is a trademark of Deere & Company Diag.

Group 15DV - Warning - Conveyor Auger Speed Diagnostics

Group 15DW - Warning - Cylinder Speed Diagnostics

Group 15DX - Warning Engine Air Filter Diagnostics

Group 15DY - Warning Engine Oil Pressure Diagnostics

Group 15DZ - Warning - Engine Speed Diagnostics

Group 15EA - Warning - Engine Temperature Diagnostics

Group 15EB - Warning - Grain Separator Speed Diagnostics

Group 15EC - Warning Grain Tank Full Diagnostics

Group 15ED - Warning-Hydraulic Oil Temperature Diagnostics

Group 15EE - Warning - Hydrostatic Charge Pressure Diagnostics

Group 15EF - Warning-Low Fuel

Group 15EG - Warning Main Gearcase Filter Restricted Diagnostics

Group 15EH - Warning - Main Gearcase Pressure Diagnostics

Group 15EI - Warning - Main Gearcase Temperature Diagnostics

Group 15EJ - Warning Parking Brake Diagnostics

Group 15EK - Warning - Separator Plugged Diagnostics

Group 15EL - Warning - Straw Chopper Speed Diagnostics

Group 15EM - Warning - Tailings Elevator Speed Diagnostics

Group 15EN - Warning - Unloading Auger Engaged Diagnostics

Group 15EO - Warning Voltage Low Diagnostics

Group 15EP - Wiper System Diagnostics

Group 20 - Connector Information (end views, numbers, location photos)

Section 250 - POWER TRAIN SYSTEM

Group 05 - General Information

Group 10 - Test Procedures and Adjustments

Group 15A - Final Drive Diagnostics

Group 15B - Transmission Diagnostics

Group 15C - Hydrostatic Diagnostics

Group 20D - Component Identification

Section 255 - FOUR WHEEL DRIVE SYSTEM

Group 05 - General Information

Group 10 - Test Procedures and Adjustments

Group 15A - Four Wheel Drive System - Type Identification

Group 15B - Four Wheel Drive Single Speed Diagnostics

Group 15C - Four Wheel Drive Two Speed Diagnostics

Group 20 - Component Identification

Section 260 - BRAKE SYSTEM

Group 05 - General Information

Group 10 - Test Procedures and Adjustments

Group 15A - Park Brake Diagnostics

Group 15B - Service Brakes Diagnostics

Group 20 - Component Identification

Section 270 - HYDRAULIC SYSTEM

Group 05 - General Information

Group 10 - Test Procedures And Adjustments

Group 15A - Basic Hydraulic System Type Identification

Group 15B - Basic Hydraulic System Diagnostics - Type A

Group 15C - Basic Hydraulic System Diagnostics - Type B

Group 15D - Basic Hydraulic System Diagnostics - Type C

Group 15E - Basic Hydraulic System Diagnostics - Type D

Group 15F - Chaff Spreader Drive Diagnostics

Group 15G - CONTOUR MASTER™ Header Tilt Diagnostics

Group 15H - Deck Plate Adjust Type Identification

Group 15I - Deck Plate Adjust Diagnostics - Type A

Group 15J - Deck Plate Adjust Diagnostics - Type B

Group 15K - Draper Belt Drive Diagnostics

Group 15L - Feeder House Gearcase Cooler Diagnostics

Group 15M - Header Raise/Lower Diagnostics

Group 15N - HYDRAFLEX™ Pressure Adjust Type Identification

Group 15O - HYDRAFLEX™ Pressure Adjust Diagnostics - Type A

Group 15P - HYDRAFLEX™ Pressure Adjust Diagnostics - Type B

Group 15Q - Hydraulic System Overheating Type Identification

Group 15R - Hydraulic System Overheating Diagnostics - Type A

Group 15S - Hydraulic System Overheating Diagnostics - Type B

Group 15T - Reel/Belt Drive Type Identification

Group 15U - Reel/Belt Drive Diagnostics - Type A

Group 15V - Reel/Belt Drive Diagnostics - Type B

Group 15W - Reel Fore/Aft Type Identification

Group 15X - Reel Fore/Aft Diagnostics - Type A

Group 15Y - Reel Fore/Aft Diagnostics - Type B

Group 15Z - Reel Raise/Lower Type Identification

Group 15AA - Reel Raise/Lower Diagnostics - Type A

Group 15AB - Reel Raise/Lower Diagnostics - Type B

Group 15AC - Reel Raise/Lower Diagnostics - Type C

Group 15AD - Reel Raise/Lower Diagnostics - Type D

Group 15AE - Reel Raise/Lower Diagnostics - Type E

Group 15AF - Reel Raise/Lower Diagnostics - Type F

Group 15AG - Reel Raise/Lower Diagnostics - Type G

Group 15AH - Reel Raise/Lower Diagnostics - Type H

Group 15AI - Threshing Speed Adjust Type Identification

Group 15AJ - Threshing Speed Adjust Diagnostics - Type A

Group 15AK - Threshing Speed Adjust Diagnostics - Type B

Group 15AL - Unloading Auger Swing Diagnostics

Group 15AM - Variable Speed Feeder House Type Identification

Group 15AN - Variable Speed Feeder House Diagnostics - Type A

Group 15AO - Variable Speed Feeder House Diagnostics - Type B

Group 15AP - Variable Speed Feeder House Diagnostics - Type C

Group 15AQ - Variable Speed Feeder House Diagnostics - Type D

Group 20 - Component Identification and Location

Section 275 - MAIN GEARCASE SYSTEM

Group 05 - General Information

Group 10 - Test Procedures and Adjustments

Group 15A - Main Gearcase Pressure Low Diagnostics

Group 15B - Main Gearcase Temperature High Diagnostics

Group 15C - Main Gearcase Filter Restricted Diagnostics

Group 15D - Separator Engage Diagnostics

Group 15E - Main Gearcase Diagnostics

Group 15F - Unloading Auger Engage Diagnostics

Group 20 - Component Identification

Section 280 - STEERING SYSTEM

Group 05 - General Information

Group 10 - Test Procedures and Adjustments

Group 15 - Steering Diagnostics

Group 20 - Component Identification

Section 290 - CLIMATRAK SYSTEM

Group 05 - General Information

Group 10 - Test Procedures and Adjustments

Group 15 - CLIMATRAK™ System Diagnostics

Group 20 - Component Identification

Section 300 - SEPARATOR SYSTEM

Group 05 - General Information

Group 15 - Separator Vibration Diagnostics

DOWNLOAD DIAGNOSIS AND TESTS MANUAL

DOWNLOAD DIAGNOSIS AND TESTS MANUAL

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 Diagnosis and Tests. Repair sections tell how to repair the components. Diagnosis 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.

This technical manual covers information unique to the SideHill 9550 Combine.

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.

Handle Fluids Safely—Avoid Fires

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.

Prepare for Emergencies

First Aid Kit

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

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).

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

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.

Acid Burns

Handle Chemical Products Safely

Material Safety Data Sheet

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Handle Starting Fluid Safely

Store Safely

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.

Avoid High-Pressure Fluids

High Pressure

Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

Park Machine Safely

Remove the Key

Before working on the machine:

Lower all equipment to the ground. Stop the engine and remove the key. Disconnect the battery ground strap. Hang a "DO NOT OPERATE" tag in operator station.

Support Machine Properly

Support Properly

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.

Wear

Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

Protect Against Noise

Noise Exposure

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Work in Clean Area

Clean Work Area

Before starting a job:

Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Illuminate Work Area Safely

Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Service Machines Safely

Moving Parts

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Construct Dealer-Made Tools Safely

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.

Do not weld tools unless you have the proper equipment and experience to perform the job.

Service Cooling System Safely

Cooling System

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Wait Before Opening High-Pressure Fuel System

High-Pressure Fuel Lines

High-pressure fluid remaining in fuel lines can cause serious injury. Only technicians familiar with this type of system should perform repairs. Before disconnecting fuel lines, sensors, or any other components between the high-pressure fuel pump and nozzles on engines with High-Pressure Common Rail (HPCR) fuel system, confirm that the fuel pressure is relieved.

Replace Safety Signs

Safety Signs

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.

Remove Paint Before Welding or Heating

Toxic Fumes

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating:

Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

Explosive Tire and Rim Parts

Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Avoid

Harmful Asbestos Dust

Asbestos Dust

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

Keep Area Clean

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

Dispose of Waste Properly

Recycle Waste

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Safety Systems

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

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