John Deere 9560 9660 Combine Workshop Repair Service Manual (TM2161) PDF - MJODTM2161.zip
This is a full-service repair guide covering John Deere 9560 and 9660 Combine models (serial numbers 705201 and up), offering the technical data needed to service, fix, and rebuild your equipment the way a professional technician would.
The workshop manual for the John Deere 9560 and 9660 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.
TM2161 - John Deere 9560 and 9660 Combines Technical Manual (Repair).pdf
TM2161 - John Deere 9560 and 9660 Combines Technical Manual (Repair).epub
Total Pages: 1,961 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
Lower Engine Repair
Cooling System
Fuel and Air System
Air Intake System
Diesel Fuel System
Electrical System
Batteries
Harness and Connector Repair
Wiring Harness Routing
Fuses, Circuit Breakers and Relays
Lighting
Operators Station
Sensors and Switches
Wiper
Alternator
Starting Motor
GREENSTAR Components
Power Train Repair
Transmission and Differential
Single Reduction Final Drive
Hydrostatic System
Cam Lobe Motor
Tires and Wheels
Power Steering and Brakes
Steering
Brakes
Hydraulic Repair
Hydraulic Reservoir
Hydraulic Pumps
Hydraulic Valves
Hydraulic Cylinders
Motors
Accumulator
Separator Shell
Gull Wing Doors
Cleaning Fan Shields
Rear Hood
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
Cylinder Drives
Straw Walkers and Crankshafts
Straw Chopper, Straw Spreader and Chaff Spreader
Shoe Supply 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 and Loading Auger Gear Case
Grain Tank and Extensions
Engine Gear Case and Control Valve Repair
Engine Gear Case and Valve
Dealer Fabricated Tools
tm2161 - 9560 and 9660 Combines 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 Agricultural Chemicals 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
Dispose of Waste Properly
Use Adequate Service Facilities
Live With Safety
Group 10: Specifications
Operating Speeds
Ground Speeds (Fast Idle) Two Speed Four Wheel Drive
Ground Speeds (Fast Idle) Two Speed Four Wheel Drive
Turning Radius
Specifications - 9560 Combine
Specifications - 9660 Combine
Dimensions
Dimension Reference Points
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
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
Sealants and Adhesives Cross-Reference 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
Diesel Fuel
Heavy Duty Diesel Engine Coolant
Storing Fuel
Supplemental Coolant Additives
Liquid Coolant Conditioner
Diesel Engine Oil
Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils
Transmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger Elevator
Grease
Lubricant Storage
Alternative and Synthetic Lubricants
Section 20: Engine
Group 05: Remove and Install Engine
Essential or Recommended Tools
Specifications
6068 John Deere Engine Repair—(9560 Combine)
6081 John Deere Engine Repair—(9660 Combines)
Remove Engine
Install Engine
Group 10: Lower Engine Repair
Remove and Install Engine Oil Pan Access Sheet
Group 15: Cooling System
Service Equipment and Tools
Specifications
6068 John Deere Engine Repair—(9560 Combine)
6081 John Deere Engine Repair—(9660 Combines)
Remove and Install Rotary Screen
Remove and Install Rotary Screen Drive
Remove and Install Rotary Screen Idler Arm and Sheaves
Adjusting Rotary Screen Knife Comb
Remove Radiator
Install Radiator
Test Radiator
Test Radiator Cap
Replace Thermostat
Repair or Replace Water Pump
Section 30: Fuel and Air System
Group 05: Air Intake System
Other Material
Specifications
John Deere Engine Repair
Remove and Install Turbocharger
Remove and Install Charge Air Cooler
Cleaning the Charge Air Cooler
Remove and Install Air Cleaner Filters
Group 10: Diesel Fuel System
Other Material
Specifications
Bleeding Engine Fuel Filter 6.8 L
Bleeding Fuel System 8.1 L (S.N. —705331)
Bleeding Fuel System 8.1 L Dual Filter System (S.N. 705332— )
Remove and Install Fuel Return Line Regulator 9560 (S.N.—710200), 9660 (S.N. —710300)
Remove Fuel Tank
Install Fuel Tank
Remove and Install Fuel Level Sensor
Remove and Install Fuel Tank Strainer
Replace Cold Weather Starting Aid Can
Remove and Install Cold Weather Starting Aid
Section 40: Electrical System
Group 05: Batteries
Essential or Recommended Tools
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: Wiring Harness Routing
Replace Harness
Cab Main Wiring Harness (S.N. —715100)
Cab Main Wiring Harness (S.N. 715101—)
Auxiliary Cab Main AUTOTRAC Wiring Harness
Left-Hand Main Wiring Harness
Right-Hand Main Wiring Harness
Engine Wiring Harness
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
9560 Engine Compartment Relay Panel Fuse Identification
9660 Engine Compartment Relay Panel Fuse Identification
9560 Engine Compartment Relay Panel Relay Identification
9660 Engine Compartment Relay Panel Relay Identification
Glow Plug Fuse
Diagnostic System Fuse For Glow Plugs
Group 25: Lighting
Safety Rules When Replacing Halogen Bulbs
Bulb Part Numbers
Cab Head Light Bulb Replacement and Adjustment (S.N. —715100)
Cab Head Light Bulb Replacement and Adjustment (S.N. 715101—)
Remove and Install High Intensity Discharge (HID-Xenon) Lights (Optional) (S.N. —715100)
Remove and Install High Intensity Discharge (HID-Xenon) Lights (Optional) (S.N. 715101—)
Remove and Install High Intensity Discharge (HID-Xenon) Ballasts (S.N. 715101—)
Auxiliary Field, Access Door, Rear Discharge, Grain Tank and Unloading Auger Work Light Bulb Replacement
Side Finder Light Bulb Replacement
Tail Light Assembly Bulb Replacement
Warning Light Bulb Replacement
Cleaning Shoe Light Bulb Replacement
Turn Signal and Maximum Tilt Indicator Light Bulb Replacement
Dome and Console Light Bulb Replacement
Warning Light Bulb Replacement
COMMANDTOUCH Cornerpost Monitor Light Bulb Replacement
Warning Display Panel Light Bulb Replacement
Header Float Gauge (Optional) Bulb Replacement
Group 30: Operators Station
Other Material
Specifications
Instruments and Controls Identification
Overhead Warning Display Panel
Remove and Install Overhead Warning Display Panel
Replace Overhead Warning Display Panel Circuit Board
Remove and Install Light Panel Dimmer Switch
Remove and Install Overhead Console Rocker Switches
Remove and Install CLIMATRAK Automatic Air Conditioning/Heater Temperature Control Switch and Fan Switch
Remove and Install Radio
Remove and Install Radio Speakers (S.N. —715100)
Remove and Install Radio Speakers (S.N. 715101—)
Remove and Install Radio Antenna (S.N. —715100)
Remove and Install Radio Antenna (S.N. 715101—)
Replace Cornerpost Main Circuit Board