John Deere 9560 STS 9660 STS 9760 STS 9860 STS Combines Workshop Repair Service Manual (TM2181) PDF - MJODTM2181.zip

A full workshop repair guide for the John Deere 9560 STS, 9660 STS, 9760 STS, and 9860 STS combines (North American models), offering dealer-level instructions for upkeep, servicing, and overhauls.

This service and repair manual for John Deere 9560 STS, 9660 STS, 9760 STS, and 9860 STS combines contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

TM2181 - John Deere Combines 9560 STS, 9660 STS, 9760 STS, 9860 STS Technical Manual (Repair).pdf

TM2181 - John Deere Combines 9560 STS, 9660 STS, 9760 STS, 9860 STS Technical Manual (Repair).epub

Total Pages: 2,219 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

MAIN SECTIONS

Foreword

General

Safety

Specifications

Tune-Up and Adjustment

Fuels and Lubricants

Engine

Remove and Install Engine

Cooling System

Lower Engine Repair

Fuel and Air Repair

Air Intake System

Diesel Fuel System

Electrical System

Batteries

Harness and Connector Repair

Wire Harness Routing

Fuses, Circuit Breakers and Relays

Lighting

Operators Station

Sensors and Switches

Wiper

Alternator

Starting Motor

Electrical Engine Control

GREENSTAR Components

Power Train Repair

Transmission and Differential

Single Reduction Final Drive-Heavy Duty

Hydrostatic System

Cam Lobe Motor

Tires and Wheels

Power Steering and Brakes

Steering

Brakes

Hydraulic Repair

Hydraulic Reservoir

Hydraulic Pumps

Hydraulic Valves

Hydraulic Valve Stack (S.N. -715300)

Hydraulic Valve Stack (S.N. 715301-)

Hydraulic Cylinders

Motors

Accumulator

Separator Shell

Gull Wing Doors

Operator Station Repair

Air Conditioning System (R134a)

System Components

Cab

Feeder House Repair

Conveyor

Top Shaft and Slip Clutch

Feeder House Drives and Reverser Gear Case

CONTOUR MASTER Tilt Cylinder

CONTOUR MASTER Tilt Frame

Separator

Separator Repair

Separator Drives

Residue Disposal

Conveyor Augers, Cleaning Fan And Chaffer And Sieve Frame

Tailings Elevator and Augers

Primary Countershaft Gear Case

Header Electromagnetic Clutch

Grain Tank and Unloading System Repair

Grain Tank Cross Augers

Unloading Auger System Drives

Vertical Unloading Auger and Lower Gear Case

Horizontal Unloading Auger and Gear Case

Clean Grain Elevator

Grain Tank and Extensions

Engine Gear Case and Control Valve Repair

Engine Gear Case and Valve

Dealer Fabricated Tools

Dealer Fabricated Tools

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

Table of Contents

Foreword

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Handling Batteries Safely

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Service Accumulator Systems Safely

Wait Before Opening High-Pressure Fuel System

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Construct Dealer-Made Tools Safely

Use Proper Tools

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Use Adequate Service Facilities

Live With Safety

Group 10: Specifications

Ground Speeds (Fast Idle) Two Speed Four Wheel Drive

Turning Radius

Operating Speeds—9560 STS

Specifications—9560 STS Combine

Dimensions—9560 STS Combine

Dimension Reference Points—9560 STS Combine

Operating Speeds—9660 STS, 9760 STS Combines

Specifications—9660 STS Combine

Specifications—9760 STS Combine

Dimensions—9660 STS, 9760 STS Combines

Dimension Reference Points—9660 STS, 9760 STS Combines

Operating Speeds—9860 STS Combine

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

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

Dimensions—9860 STS Combine

Dimension Reference Points—9860 STS Combine

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Sealants and Adhesives Cross-Reference Chart

Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Face Seal Fitting Torque Chart—Standard Pressure Applications

Metric Face Seal Fitting Torque Chart—High Pressure Applications

SAE Face Seal Fitting Torque Chart—Standard Pressure Applications

SAE Face Seal Fitting Torque Chart—High Pressure Applications

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications

External Hexagon Port Plug Torque Chart

Prevent Hydraulic System Contamination

Check Oil Lines and Fittings

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

Group 15: Tune-Up and Adjustment

Tune-Up and Adjustment

Care and Maintenance of Belts

Defective Belts

Group 20: Fuels and Lubricants

Handle Fuel Safely—Avoid Fires

Handling and Storing Diesel Fuel

Diesel Fuel

BioDiesel Fuel

Lubricity of Diesel Fuel

Testing Diesel Fuel

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Operating in Warm Temperature Climates

Supplemental Coolant Additives

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

Testing Diesel Engine Coolant

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

Diesel Engine Oil — Tier 2 and Stage II

Oilscan™ and CoolScan™

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

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

Grease

Brake Fluid

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Section 20: Engine

Group 05: Remove and Install Engine

Essential or Recommended Tools

Specifications

John Deere Engine Repair

Remove Engine—6.8 L

Install Engine—6.8 L

Remove Engine—8.1 L

Install Engine—8.1 L

Remove Engine—9.0 L

Install Engine—9.0 L

Remove Engine—12.5 L

Install Engine—12.5 L

Group 10: Cooling System

Essential or Recommended Tools

Specifications

John Deere Engine Repair

Rotary Screen Drive

Rotary Screen Idler Arm and Sheaves

Remove and Install Upper and Lower Air Scoops

Remove and Install Rotary Screen

Adjusting Rotary Screen Knife Comb

Remove Radiator—6.8 L Engine

Install Radiator—6.8 L Engine

Remove Radiator—8.1 L Engine

Install Radiator—8.1 L Engine

Remove Radiator—9.0 L Engine

Install Radiator—9.0 L Engine

Remove Radiator—12.5 L Engine

Install Radiator—12.5 L Engine

Test Radiator

Test Radiator Cap

Replace Thermostats

Repair or Replace Water Pump

Group 15: Lower Engine Repair

Remove and Install Engine Oil Pan Access Sheet

Section 30: Fuel and Air Repair

Group 05: Air Intake System

Other Material

Specifications

John Deere Engine Repair

Remove and Install Turbocharger—8.1 L Engine

Remove and Install Turbocharger—6.8 L and 9.0 L Engine

Remove and Install Turbocharger—12.5 L Engine

Turbocharger Repair

Remove and Install Charge Air Cooler—8.1 L Engine

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

Remove and Install Charge Air Cooler—12.5 L Engine

Cleaning the Charge Air Cooler

Group 10: Diesel Fuel System

Other Material

Specifications

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

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

Bleed Fuel System—12.5 L Engine

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

Remove and Install Fuel Tank

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

Remove and Install Fuel Tank Strainer and Breather

Replace Cold Weather Starting Aid Can

Remove and Install Cold Weather Starting Aid

Section 40: Electrical System

Group 05: Batteries

Prevent Battery Explosions

Handling Batteries Safely

Prevent Damage to Electrical Systems

Checking Electrolyte Specific Gravity

Battery Replacement

Remove and Install Batteries

Connecting Booster Batteries

Charging Batteries

Connecting Battery Cables

Group 10: Harness and Connector Repair

Essential or Recommended Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Electrical System Visual Inspection

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

Electrical Connector / Wiring Harness Handling and Repair

Repair Procedure R-A

Repair Procedure R-B

Repair Procedure R-C

Repair Procedure R-D

Repair Procedure R-E

Repair Procedure R-F

Repair Procedure R-G

Repair Procedure R-I

Repair Procedure R-J

Repair Procedure R-K

Repair Procedure R-M

Repair Procedure R-N

Repair Procedure R-AE

Group 15: Wire Harness Routing

Replace Harness

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

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

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

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

Left-Hand Main Wiring Harness

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

Right-Hand Main Wiring Harness

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

Engine Wiring Harness

Engine Wiring Harness (Tier III Cooling Package)

Group 20: Fuses, Circuit Breakers and Relays

Specifications

Basic Operation

Power Distribution Board System Basic Description

Circuit Board Replacement

Relays

Power Distribution Board Relay Identification

Engine Compartment Relay Panel Fuse Identification

Engine Compartment Relay Panel Identification

Group 25: Lighting

Safety Rules When Replacing Halogen Bulbs

Bulb Part Numbers