JOHN DEERE 9650 CTS COMBINE TM2021 PDF MANUAL

9650 CTS Combine - Repair

REPAIR TECHNICAL MANUAL Combines models 9650CTS (S.N.:695401-700400) TM2021 07 APR 10 (ENGLISH)

For complete service information also see: 9650 CTS Combines Diagnosis and TestsTM2022 PowerTech 8.1 L Diesel Engines Base Engine CTM86 Alternators and Starting MotorsCTM77 OEM Engine AccessoriesCTM67 PowerTech 8.1L Diesel Engines Level 9 Electronic Fuel System With Denso HighCTM255 Pressure Common Rail

John Deere Agriculture

9650 CTS Combine - Repair

(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 - Lower Engine Repair Group 15 - Cooling System Section 30 - FUEL AND AIR SYSTEM 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 - Wiring 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 - GREENSTAR Components Section 50 - POWER TRAIN REPAIR Group 05 - Transmission and Differential Group 10 - Single Reduction Final Drive 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 20 - Hydraulic Cylinders Group 25 - Motors Group 30 - Accumulator Section 80 - SEPARATOR SHELL Group 05 - Gull Wing Doors Group 10 - Cleaning Fan Shields Group 15 - Rear Hood and Lower Panels 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 Group 10 - Top Shaft and Slip Clutch <- Go to Global Table of contents

9650 CTS Combine - Repair

9650 CTS Combine - Repair

(g) by Belgreen v2.1

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 - Beaters Group 15 - Cylinder Drives Group 20 - Tine Separator Module Group 25 - Tine Separators Group 30 - Tine Separator Gear Cases Group 35 - Engine Gear Case to Module Drives Group 40 - Shoe Supply Augers, Cleaning Fan, Chaffer and Sieve Frames Group 45 - Straw Chopper, Straw Spreader and Chaff Spreader Group 50 - Tailings Elevator and Augers Group 55 - Primary Countershaft Gear Case Group 60 - 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 and Loading Auger Gear Case 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

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9650 CTS Combine - Repair

For the full PDF version of this manual, Please click on the above download PDF button.

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9650 CTS Combine - Repair

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.

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Section 10 page 1

9650 CTS Combine - Repair

9650 CTS Combine - Repair

(g) by Belgreen v2.1

Section 10 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Remove Paint Before Welding or Heating ............................................................................................. 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 2 Prevent Battery Explosions ................................................................................................................... 3 Handling Batteries Safely ..................................................................................................................... 3 Prepare for Emergencies ...................................................................................................................... 5 Prevent Acid Burns ............................................................................................................................... 6 Avoid High-Pressure Fluids ................................................................................................................... 6 Service Accumulator Systems Safely .................................................................................................... 7 Wait Before Opening High-Pressure Fuel System ................................................................................. 8 Park Machine Safely ............................................................................................................................. 8 Support Machine Properly .................................................................................................................... 8 Wear Protective Clothing .................................................................................................................... 10 Service Machines Safely ..................................................................................................................... 10 Work In Ventilated Area ...................................................................................................................... 11 Illuminate Work Area Safely ............................................................................................................... 11 Replace Safety Signs .......................................................................................................................... 11 Use Proper Lifting Equipment ............................................................................................................. 12 Service Tires Safely ............................................................................................................................ 13 Avoid Harmful Asbestos Dust ............................................................................................................. 13 Work in Clean Area ............................................................................................................................. 14 Practice Safe Maintenance ................................................................................................................. 15 Use Proper Tools ................................................................................................................................. 15 Dispose of Waste Properly .................................................................................................................. 16 Use Adequate Service Facilities .......................................................................................................... 16 Live With Safety ................................................................................................................................. 17 Group 10 - Specifications ..................................................................................................................... 18 Operating Speeds ............................................................................................................................... 18 Ground Speeds (Fast Idle) Two Speed Four Wheel Drive .................................................................... 19 Ground Speeds (Fast Idle) Two Speed Four Wheel Drive .................................................................... 20 Ground Speeds (Separator Full Load) ................................................................................................. 20 Turning Radius ................................................................................................................................... 20 Specifications ..................................................................................................................................... 22 Dimensions ......................................................................................................................................... 23 Dimension Reference Points ............................................................................................................... 24 Unified Inch Bolt and Screw Torque Values ........................................................................................ 25 Metric Bolt and Screw Torque Values ................................................................................................. 26 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................ 26 Metric Face Seal Fitting Torque Chart—Standard Pressure Applications ............................................ 28 Metric Face Seal Fitting Torque Chart—High Pressure Applications ................................................... 29 SAE Face Seal Fitting Torque Chart—Standard Pressure Applications ................................................ 30 SAE Face Seal Fitting Torque Chart—High Pressure Applications ....................................................... 31 Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications ................................. 31 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications ............................. 33 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications .................................... 34 External Hexagon Port Plug Torque Chart .......................................................................................... 35 Sealants and Adhesives Cross-Reference Chart ................................................................................. 36 Prevent Hydraulic System Contamination .......................................................................................... 36

<- Go to Global Table of contents

9650 CTS Combine - Repair

9650 CTS Combine - Repair

(g) by Belgreen v2.1

Check Oil Lines and Fittings ............................................................................................................... 36 Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems ....................................................................................................................................... 37 Group 15 - Tune Up and Adjustment .................................................................................................. 39 Tune-Up and Adjustment .................................................................................................................... 39 Care and Maintenance of Belts ........................................................................................................... 40 Defective Belts ................................................................................................................................... 41 Group 20 - Fuels and Lubricants ......................................................................................................... 44 Diesel Fuel .......................................................................................................................................... 44 Heavy Duty Diesel Engine Coolant ..................................................................................................... 44 Storing Fuel ........................................................................................................................................ 45 Supplemental Coolant Additives ......................................................................................................... 45 Liquid Coolant Conditioner ................................................................................................................. 46 Diesel Engine Oil ................................................................................................................................ 47 Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils ......................... 48 Transmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger Elevator ..................................................................................................................................................... 49 Grease ................................................................................................................................................ 51 Lubricant Storage ............................................................................................................................... 51 Alternative and Synthetic Lubricants .................................................................................................. 52

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9650 CTS Combine - Repair

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.

Remove Paint Before Welding or Heating

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Section 10 page 1

9650 CTS Combine - Repair

Section 10 - GENERAL

Group 05: Safety

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.

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. <- Go to Section TOC

Section 10 page 2

9650 CTS Combine - Repair

Section 10 - GENERAL

Group 05: Safety

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 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

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Section 10 page 3

9650 CTS Combine - Repair

Section 10 - GENERAL

Group 05: Safety

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.

Caution Acid

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Section 10 page 4

9650 CTS Combine - Repair

Section 10 - GENERAL

Group 05: Safety

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.Wash hands after handling.

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.

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Section 10 page 5

9650 CTS Combine - Repair

Section 10 - GENERAL

Group 05: Safety

Prevent Acid Burns

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.

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Section 10 page 6

9650 CTS Combine - Repair

Section 10 - GENERAL

Group 05: Safety

Avoid High-Pressure Fluids

High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury.

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

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

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

Service Accumulator Systems Safely

Hydraulic Accumulator Escaping fluid or gas from systems with pressurized accumulators that are used in air conditioning, hydraulic, and air brake systems can cause serious injury. Extreme heat can cause the accumulator to burst, and pressurized lines can be accidentally cut. Do not weld or use a torch near a pressurized accumulator or pressurized line.

Relieve pressure from the pressurized system before removing accumulator.

Relieve pressure from the hydraulic system before removing accumulator. Never attempt to relieve hydraulic system or accumulator pressure by loosening a fitting.

Accumulators cannot be repaired.

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Section 10 page 7

9650 CTS Combine - Repair

Section 10 - GENERAL

Group 05: Safety

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, wait a minimum of 15 minutes after engine is stopped.

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

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Section 10 page 8

9650 CTS Combine - Repair

For the full PDF version of this manual, Please click on the above download PDF button.