John Deere 9540 9560 9580 9640 9660 9680 CWS WTS Combine Workshop Repair Service Manual PDF (TM4697) - MJODTM4697.zip
An all-inclusive service manual covering John Deere Combine models 9540 CWS, 9540 WTS, 9640 CWS, 9640 WTS, 9580 CWS, 9580 WTS, 9680 CWS, 9680 WTS, 9660 CWS, 9660 WTS, 9560 CWS and 9560 WTS, packed with the workshop detail needed to service, fix, and overhaul these machines the way trained technicians do.
The workshop repair manual for John Deere Combines 9540, 9560, 9580, 9640, 9660 and 9680 CWS & WTS 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.
TM4697 - John Deere Combines 9540, 9560, 9580, 9640, 9660, 9680 CWS & WTS Technical Manual (Repair).PDF
TM4697 - John Deere Combines 9540, 9560, 9580, 9640, 9660, 9680 CWS & WTS Technical Manual (Repair).EPUB
Total Pages: 1,710 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
General
Safety
Identification Number Location
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
Operator`s 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
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
Accumulator
Separator Shell
Gull Wing Doors
Rear Hood
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
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
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
tm4697 - 9540, 9560, 9580, 9640, 9660, 9680 WTS and CWS 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
Prepare for Emergencies
Prevent Acid Burns
Avoid High-Pressure Fluids
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
Avoid Heating Near Pressurized Fluid Lines
Remove Paint Before Welding or Heating
Use Proper Tools
Practice Safe Maintenance
Dispose of Waste Properly
Avoid Harmful Asbestos Dust
Service Tires Safely
Protect Against Noise
Live With Safety
Group 10: Identification Number Location
Type Plates
Combine Type Plate
Engine Serial Number
Hydrostatic Drive Unit Pump
Hydrostatic Drive Unit Motor
2 Speed 4-Wheel Drive Motor
Engine Gear Case
Transmission
Group 15: Specifications
Operating Speeds
Ground Speeds
Turning Radius
Specifications - 9540 and 9560 (S.N. 074502-) Combines
Specifications - 9560 (S.N. -074501), 9580, 9640, 9660 and 9680 Combines
Dimensions
Dimension Reference Points
Metric Bolt and Cap Screw Torque Values
Unified Inch Bolt and Cap 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
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 20: Tune Up and Adjustment
Tune-Up and Adjustment
Care and Maintenance of Belts
Defective Belts
Group 25: 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
John Deere Engine Repair
Remove Engine
Install Engine
Group 10: Lower Engine Repair
Remove and Install Engine Oil Pan Access Sheet
Group 15: Cooling System
Specifications
John Deere Engine Repair
Remove and Install Rotary Screen Drive
Remove and Install Rotary Screen Idler Arm and Sheaves
Remove and Install Rotary Screen
Remove and Install Rotary Screen Brush Kit (Optional)
Remove and 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
Remove and Install Air Cleaner Filters
Group 10: Diesel Fuel System
Other Material
Specifications
Remove Fuel Tank
Remove and Install Fuel Level Sensor
Remove and Install Fuel Tank Strainer
Remove Fuel Tank Outlet Screen
Install Fuel Tank Outlet Screen
Bleeding Engine Fuel Filter (9540 Combine)
Bleeding Engine Fuel Filter (9560 Combine S.N. 074502-)
Bleeding the Fuel System (9560 S.N. -074501, 9580, 9640, 9660 and 9680 Combines)
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, Clean and Install Batteries
Connecting Booster Batteries
Charging Batteries
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 WEATHER PACK Connector
Remove Connector Body from Blade Terminals
Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors
Repair (Push Type) METRI-PACK Connectors
Repair CPCCPC is a trademark of AMP Inc. , Large MATE-N-LOCMATE-N-LOC is a trademark of AMP Inc. and METRIMATEMETRIMATE is a trademark of AMP Inc. Pin Type Connectors
Repair CPC Blade Type Connectors
Repair Small MATE-N-LOC Socket Connector
Repair Small MATE-N-LOC Pin Connector
Repair DEUTSCH Connectors
Repair CINCH Connectors
Repair Relay Panel Connectors
Repair Reel Reversing Valve Connector
Group 15: Wiring Harness Routing
Replace Harness
Cab Main Wiring Harness
Left-Hand Main Wiring Harness
Right-Hand Main Wiring Harness, With GREENSTARGREENSTAR is a trademark of Deere & Company
Engine Wiring Harness - Reference
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 Relay Identification
Glow Plug Fuse (9560 S.N. 074502-)
Diagnostic System Fuse For Glow Plugs (9560 S.N. 074502-)
Group 25: Lighting
Safety Rules When Replacing Halogen Bulbs
Cab Head Light Bulb Replacement and Adjustment
Remove and Install HID-Xenon Lights (Optional) (S.N. 074502-)
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
CommandTouchCommandTouch is a trademark of Deere & Company CornerPost Monitor Light Bulb Replacement
Warning Display Panel Light Bulb Replacement
Group 30: Operator's Station
Other Material
Specifications
Instruments and Controls Identification
Overhead Warning Display Panel
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
Remove and Install Radio
Remove and Install Radio Speaker
Remove and Install Radio Antenna (S.N. -074501)
Remove and Install Radio Antenna (S.N. 074502-)
Replace Cornerpost Main Circuit Board
Remove Header Control Module
Remove Automatic Combine Adjustment (ACA) Display (S.N. 074502-)
Remove Performance Monitor and Digital Tachometer Module
COMMANDTOUCH Console Controls
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 ClimaTrak ClimaTrak is a trademark of Deere & Company Solar Sensor
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