John Deere 9560 STS, 9660 STS, 9760 STS, 9860 STS Combines Manual TM2181 - PDF DOWNLOAD

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 DiagnosisTM2182 PowerTech 8.1 L Diesel Engines Base Engine CTM86 Alternators and Starting MotorsCTM77 PowerTech 9.0 L OEM Diesel Engines Base Engine RepairCTM400 PowerTech 9.0 L Diesel Engines Level 14 Electronic Fuel System With Denso HPCRCTM385 PowerTech Plus 4.5L and 6.8L Diesel Engines Level 14 Electronic Fuel SystemCTM320 With Denso HPCR PowerTech 8.1L Diesel Engines Level 9 Electronic Fuel System With Denso HighCTM255 Pressure Common Rail PowerTech 10.5 L & 12.5 L Diesel Engines, Level 6 Electronic Fuel Systems with LucasCTM188 EUIs 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, (BaseCTM104 Engine) 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

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TM2181-REPAIR TECHNICAL MANUAL

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

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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.

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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

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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

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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

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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

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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.

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Section 10 page 3

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Caution Acid

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. <- Go to Section TOC

Section 10 page 4

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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

TM2181-REPAIR TECHNICAL MANUAL

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

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.)

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.

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Section 10 page 7

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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.

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Section 10 page 8

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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Section 10 page 9

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Wear Protective Clothing

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.

Work in Clean Area

Clean Work Area

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Section 10 page 10

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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.

Work In Ventilated Area

Engine exhaust fumes 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

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Section 10 page 11

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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

Proper Lifting Equipment <- Go to Section TOC

Section 10 page 12

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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Section 10 page 13

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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Section 10 page 14

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Service Tires Safely

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

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Section 10 page 15

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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Section 10 page 16

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Practice Safe Maintenance

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.

Construct Dealer-Made Tools Safely

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Section 10 page 17

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

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

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Section 10 page 18

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

Use Adequate Service Facilities Keep the service area clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment.

Make sure the service area is adequately vented.

Periodically check the shop exhaust system for leakage. Engine exhaust gas is dangerous.

Be sure all electrical outlets and tools are properly grounded.

Use adequate light for the job at hand.

Service the machine on a level, hard-surfaced area.

Use lifting equipment and safety stands which have adequate strength for the job being performed.

Live With Safety

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Section 10 page 19

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 10: Specifications

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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Section 10 page 20

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 10: Specifications

Group 10 - Specifications Ground Speeds (Fast Idle) Two Speed Four Wheel Drive →NOTE: Speeds shown are for combines equipped with 18.4 x 26 R1 rear tires. Except combines equipped with 35.5 x 32 R2 drive tires are shown with 28L x 26 R2 rear tires.

Ground Speeds—Fast Idle Speed Front Tire

2WD

30.5 x 32 R1

X Low High

30.5 x 32 R1 800/65R32

X

800/65R32

Low High

30.5L x 32R2 30.5L x 32 R2

2-Speed 4WD

X Low High

30.5L x 32 R3

in

Km/h

First Gear

(mph) Second Gear

Third Gear

6.1 (3.8)

11.4 (7.1)

30.4 (19.0)

4.7 (2.9) 5.4 (3.4) 6.1 (3.8)

7.3 (4.6) 9.1 (5.7) 11.4 (7.1)

12.1 (7.6) 18.1 (11.3) 30.4 (19.0)

4.7 (2.9) 5.4 (3.4) 6.3 (3.9)

7.3 (4.6) 9.1 (5.7) 11.7 (7.3)

12.1 (7.6) 18.1 (11.3) 31.2 (19.5)

4.8 (3.)

5.5 (3.4) 5.8 (3.6)

7.4 (4.6) 9.3 (5.8) 10.8 (6.8)

12.3 (7.7) 18.5 (11.6) 28.8 (18.0)

18.4 x 38 R1

X

5.9 (3.7)

11.1 (6.9)

29.5 (18.4)

18.4 x 38 R1

X

4.6 (2.9) 5.2 (3.3) 6.1 (3.8)

7.1 (4.4) 8.9 (5.6) 11.4 (7.1)

11.9 (7.4) 17.8 (11.1) 30.4 (19.0)

7.3 (4.6) 9.1 (5.7) 11.4 (7.1)

12.2 (7.6) 18.3 (11.4) 30.4 (19.0)

7.3 (4.6) 9.1 (5.7) 11.8 (7.4)

12.1 (7.6) 18.1 (11.3) 31.3 (19.6)

7.4 (4.6) 9.3 (5.8) 12.7 (7.9)

12.2 (7.6) 18.4 (11.5) 33.8 (21.1)

8.1 (5.1) 10.1 (6.3) 10.8 (6.8)

13.5 (8.4) 20.2 (12.6) 28.8 (18.0)

7 (4.4) 8.7 (5.4)

11.8 (7.4) 17.5 (10.9)

Low High

18.4 x 38 R2 18.4 x 38 R2

X

20.8 x 38 R1

Low High

20.8 x 38 R1 18.4 x 42 R1

X Low High

18.4 x 42 R1 35.5 x 32 R2

X

35.5 x 32 R2 68

x

50-32,

32, HF3

4.7 (2.9) 5.4 (3.4) 6.3 (3.9) 4.8 (3.0) 5.5 (3.4) 6.8 (4.3)

Low High

5.2 (3.3) 6 (3.8) 5.8 (3.6)

Low High

4.5 (2.8) 5.1 (3.2)

X

HF3 68 x 50-

4.7 (2.9) 5.4 (3.4) 6.1 (3.8)

X Low High

Turning Radius Turning Radius Combin e Model

Front Tires

Rear Tires

9560 STS

30.5L-32

18.4-26

9660 STS, 97560 STS and 9860 STS

30.5L-32

18.4-26

<- Go to Section TOC

Non-Powered Rear Axle

Two Speed Powered Rear Axle

7.4 m (24 ft 2 in.)

7.73 m (25 ft 3 in.)

7.4 m (24 ft 2 in.)

8.19 m (26 ft 10 in.)

Section 10 page 21

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 10: Specifications

Operating Speeds—9560 STS Speeds shown are average and can vary from machine to machine. Speeds are rated at high idle with separator engaged, no load.

Operating speeds specifications and design subject to change without notice.

Engine Speeds Engine Speed Slow Idle (Separator Off) (6.8 L Engine)

1300

Slow Idle (Separator Off) (8.1 L Engine)

rpm

Mid Speed (Separator Off) (6.8 L Engine)

1200

Mid Speed (Separator Off) (8.1 L Engine)

rpm

Fast Idle (Separator Off) (6.8 L Engine)

1850

Fast Idle (Separator Off) (8.1 L Engine)

rpm

Full Load Rated Speed (6.8 L Engine)

1680

Full Load Rated Speed (8.1 L Engine)

rpm 2550

Separator Drive Shaft Speed

rpm

Separator Drive Shaft Speed

15462340 rpm rpm

Main Countershaft Speed

2400

Main Countershaft Speed

1546 rpm rpm 2200

Single Tine Separator Speeds

rpm

Single Tine Separator Speed High Range

480

Low Range

rpm 230 - 600

Feeder House Lower Shaft Sprocket Speeds

-

1300

rpm

Feeder House Lower Shaft Speed Standard Variable Speed Heavy Duty Variable Speed Fixed Speed

520

-

780

rpm

520

-

780 rpm 520 rpm

Fixed Speed Feeder House Drive Chain Speeds Fixed Speed Feeder House Drive Chain Speed 22 Tooth Fixed Speed Chain

48

26 Tooth Fixed Speed Chain

rpm

38 Tooth Fixed Speed Chain (Optional)

57 rpm

Feed Accelerator Speeds

83

Feed Accelerator Speed

rpm

Feed Accelerator

440/800

Feed Accelerator (Optional Slow Speed)

rpm 320/790

Discharge Beater Speeds

rpm

Discharge Beater Speed

<- Go to Section TOC

849 rpm

Section 10 page 22

TM2181-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 10: Specifications

Jackshaft Speeds Jackshaft Speed Right-Hand Jackshaft, Front

532

Right-Hand Jackshaft, Rear

rpm 532

Cleaning Fan Speeds

rpm

Cleaning Fan Speed Standard Speed

500

Special Slow Speed

-

1200

rpm 300 - 600 rpm

Elevator Speeds Elevator Speed Clean Grain Elevator

400

Clean Grain Loading Auger

rpm

Tailings Elevator, Lower Auger

424

Tailings Elevator, Upper Auger

rpm

Shoe Drive

405

Conveyor Augers

rpm 640

Unloading System Speeds

rpm

Unloading System Speed

297

Unloading System Countershaft

rpm 1087 rpm

Unloading Auger Gear Box, Input Shaft

433 450 rpm

Unloading Vertical Auger

rpm 450 rpm

Unloading Outer Auger

450 rpm

Grain Tank Horizontal Augers

420 rpm

Chopper Speeds Chopper Speed Chopper/Discharge Beater Jackshaft

2002 rpm

Chopper (Two Speed)

<- Go to Section TOC

1603/2500 rpm

Section 10 page 23

TM2181-REPAIR TECHNICAL MANUAL

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