John Deere 9540i 9560i 9580i 9640i 9660i 9680i WTS 9660 9780i CTS Hillmaster Combines Workshop Repair Service Manual (TM8090) - MJODTM8090.zip

The complete service and repair guide for John Deere Combines 9660, 9540i, 9560i, 9580i, 9640i, 9660i, 9680i WTS, 9780i CTS & Hillmaster offers workshop-level details to help you keep up with maintenance, fix issues, and service your machine the way trained technicians do.

Covering John Deere Combines 9660, 9540i, 9560i, 9580i, 9640i, 9660i, 9680i WTS, 9780i CTS, this workshop service and repair manual 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.

TM8090 - John Deere Combines 9660, 9540i, 9560i, 9580i, 9640i, 9660i, 9680i WTS, 9780i CTS Technical Manual (Repair).PDF

TM8090 - John Deere Combines 9660, 9540i, 9560i, 9580i, 9640i, 9660i, 9680i WTS, 9780i CTS Technical Manual (Repair).EPUB

Total Pages: 1,811 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

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

Harness and Connector Repair

Wiring Harness Routing

Fuses, Circuit Breakers and Relays

Lighting

Operator`s Station

Sensors and Switches

Wiper

Alternator

Starting Motor

GREENSTAR Components

Power Train Repair

Transmission and Differential

Final Drive

Hydrostatic System

Cam Lobe Motor

HILLMASTER II

Power Steering and Brakes

Steering

Brakes

Trailer Hitch

Hydraulic Repair

Hydraulic Reservoir

Hydraulic Pumps

Hydraulic Valves

Hydraulic Cylinders

HILLMASTER II Hydraulic Cylinder

Motors

Accumulators

Separator Shell

Gull Wing Doors

Rear Hood WTS

Rear Hood CTS

Operator`s 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

HEADERTRAK Tilt Cylinder and Frame

HILLMASTER II Tilt Cylinder and Frame

Separator WTS

Separator Repair

Cylinder Drives

Straw Walkers and Crankshafts

Straw Chopper and Chaff Spreader

Shoe Supply Augers, Cleaning Fan and Chaffer and Sieve Frame

Tailings Elevator and Augers

Primary Countershaft Gear Case

Header Electromagnetic Clutch

Separator CTS

Beaters

Engine Gearbox to Module Drives

Tine Separator Module

Tine Separator Gearboxes

Shoe Supply Augers, Chaffer and Sieve Frame

Straw Chopper

Grain Tank and Unloading System

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

Dealer Fabricated Tools

tm8090 - 9540i, 9560i, 9580i, 9640i, 9660i, 9680i, and9780i CTS including Hillmaster Combines Repair

Table of Contents

Foreword

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Prevent Battery Explosions

Prepare for Emergencies

Handle Fluids Safely—Avoid Fires

Prevent Acid Burns

Avoid High-Pressure Fluids

Park Machine Safely

Live With Safety

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

Service Tires Safely

Avoid Heating Near Pressurized Fluid Lines

Remove Paint Before Welding or Heating

Use Proper Tools

Practice Safe Maintenance

Protect Against Noise

Dispose of Waste Properly

Avoid Harmful Asbestos Dust

Group 10: Specifications

Operating Speeds

Specifications - 9540i, 9560i WTS

Specifications - 9580i, 9640i, 9660i, 9680i WTS

Specifications - 9780i CTS

Dimension Reference Points (WTS)

Dimensions (WTS)

Dimension Reference Points (CTS)

Dimensions (CTS)

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Flat Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Flat Face Seal Fitting Torque Chart—Standard Pressure Applications

Metric Flat Face Seal Fitting Torque Chart—High Pressure Applications

SAE Flat Face Seal Fitting Torque Chart—Standard Pressure Applications

SAE Flat 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

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

Group 15: Fuels and Lubricants

Diesel Fuel

Storing Fuel

Diesel Engine Coolant

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 and Two-Speed Separator Drive Gear Cases

Grease

Lubricant Storage

Alternative and Synthetic Lubricants

Section 20: Engine

Group 05: Remove and Install Engine

Essential or Recommended Tools

Specifications

Remove Engine

Install Engine

Group 10: Lower Engine Repair

Remove and Install Engine Oil Pan Access Sheet (WTS)

Remove and Install Engine Oil Pan Access Sheet (CTS)

Group 15: Cooling System

Remove and Install Rotary Screen

Remove and Install Rotary Screen Drive

Remove and Install Rotary Screen Idler Arm and Sheaves

Remove and Install Rotary Screen Brush Kit (Optional)

Remove and Install Radiator (WTS)

Remove and Install Radiator (CTS)

Test Radiator

Test Radiator Cap

Replace Thermostat

Repair or Replace Water Pump

Section 30: Fuel and Air System

Group 05: Air Intake System

Remove and Install Charge Air Cooler (WTS)

Remove and Install Charge Air Cooler (CTS)

Group 10: Diesel Fuel System

Specifications

Remove Fuel Tank

Bleeding Engine Fuel Filter (9540i Combine)

Bleeding Engine Fuel Filter (9560i Combine)

Bleeding the Fuel System (9580i, 9640i, 9660i, 9680i WTS and 9780i CTS)

Section 40: Electrical System

Group 05: Harness and Connector Repair

Essential or Recommended Tools

Other Material

Use Electrical Insulating Compound

Connector Repair Procedures

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 10: Wiring Harness Routing

Cab Main Wiring Harness

Left-Hand Main Wiring Harness

Right-Hand Main Wiring Harness, With GREENSTAR GREENSTAR is a trademark of Deere & Company

Engine Wiring Harness - Reference

Group 15: Fuses, Circuit Breakers and Relays

Circuit Board Replacement

Glow Plug Fuse (9560i WTS)

Diagnostic System Fuse For Glow Plugs (9560i WTS)

Group 20: Lighting

Safety Rules When Replacing Halogen Bulbs

Cab Head Light Bulb Replacement and Adjustment

Remove and Install HID-Xenon Light

Auxiliary Field and Access Door, Work Light Bulb Replacement

Rear Residue Discharge Light Bulb Replacement

Side Finder Light Bulb Replacement

Grain Tank and Unloading Auger Light Bulb Replacement

Cleaning Shoe Light Bulb Replacement

Turn Signal and Maximum Tilt Indicator Light Bulb Replacement

Dome and Console Light Bulb Replacement

CommandTouch CommandTouch is a trademark of Deere & Company CornerPost Monitor Light Bulb Replacement

Warning Display Panel Light Bulb Replacement

Group 25: Operator's Station

Specifications

Remove and Install Overhead Console

Replace Overhead Warning Display Panel Circuit Board

Remove and Install Light Panel Dimmer Switch

Remove and Install Overhead Display Rocker Switches

Remove and Install ClimaTrak ClimaTrak is a trademark of Deere & Company Automatic Air Conditioning/Heater Temperature Control Switch and Fan Switch

Replace Cornerpost Main Circuit Board

Remove Header Control Module

Remove Automatic Combine Adjustment (ACA) Display

Remove Performance Monitor and Digital Tachometer Module

Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company Console

Remove and Install Header and Separator Engage Switches

Remove and Install DIAL-A-SPEED DIAL-A-SPEED is a trademark of Deere & Company and Header Height/Ground Pressure Control Switches

Remove and Install Back Light Bulbs for DIAL-A-SPEED and Header Height/Ground Pressure Control Switches

Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company Console Membrane Switches

Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company Console Circuit Board

Replace Neutral Safety Switch

Replace Mini Harness

Remove and Install Multi-Function Handle

Remove and Install Start Switch

Remove and Install Horn Switch

Remove and Install Mirrors

Remove and Install Mirror Switch

Group 30: Sensors and Switches

Other Material

Shaft Speed Sensor Locations

Shaft Speed Sensor Locations (WTS)

Shaft Speed Sensor Locations (CTS)

Remove and Install Conveyor Auger, Tailings Elevator, Grain Elevator and Grain Separator Sensors

Remove and Install Cleaning Fan, Cylinder Speed and Feeder House Backshaft Speed Sensors

Remove and Install Straw Chopper Sensor

Remove and Install Grain Tank Sensor

Remove and Install Tailings Sensor

Remove and Install (Shoe/Separator) VisionTrak VisionTrak is a trademark of Deere & Company Sensors

Remove and Install (Return to Cut and Tilt) Header Height/Ground Pressure Control Sensors

Remove and Install Coolant Temperature Sensor

Remove and Install Coolant Temperature Sensor

Remove and Install Fuel Level Sensor

Remove and Install Park Brake Switch

Remove and Install Air Filter Restriction Switch

Remove and Install Engine Gear Case Temperature and Pressure Switches

Remove and Install Hydro Charge Pressure Switch

Remove and Install Hydraulic Reservoir Temperature Sensor

Remove and Install Engine Oil Pressure Switch

Remove and Install Service and Cleaning Shoe Light Switch

Remove and Install Chaffer/Sieve Sensor/Adjusting Motor

Group 35: Wiper

Specifications

Remove and Install Wiper Motor

Remove and Install Windshield Washer

Group 40: Alternator

Specifications

Remove and Install Alternator

Group 45: Starting Motor

Specifications

Remove and Install Starting Motor

Remove and Install Starter Relay

Group 50: GREENSTAR Components

Specifications

Remove and Install GREENSTAR Mass-Flow Sensor

Remove and Install GREENSTAR Paddle Wheel

Remove and Install GREENSTAR Moisture Sensor

Remove and Install Position Receiver

Section 50: Power Train Repair

Group 05: Transmission and Differential

Other Material

Specifications

Remove and Repair Shifter Forks and Shifter Cam

Install Shifter Forks and Shifter Cam