Complete service repair manual for John Deere Combines 9660, 9540i, 9560i, 9580i, 9640i, 9660i, 9680i WTS, 9780i CTS & Hillmaster, with workshop information to maintain, repair, and service like professional mechanics.

John Deere Combines 9660, 9540i, 9560i, 9580i, 9640i, 9660i, 9680i WTS, 9780i CTS workshop service & repair manual includes:
* 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

Remove and Install Transmission Lube Pump

Remove and Install Suction Screen

Remove Transmission

Transmission Recondition

Disassemble and Repair Transmission

Assemble Transmission

Install Transmission

Remove and Install Gearshift Lever and Linkage

Adjust Gearshift Linkage

Group 10: Final Drive

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive

Disassemble and Assemble Final Drive

Adjust Spindle Bearing (Preferred Method)

Adjust Spindle Bearing (Alternate Method)

Group 15: Hydrostatic System

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Flushing the Hydrostatic System

Remove and Install Hydrostatic Motor

Disassemble Hydrostatic Motor

Replace Cylinder Block Spring

Assemble Motor

Remove and Install Motor Valve Block (Manifold)

Repair Motor Valve Block

Remove Hydrostatic Pump

Disassemble Hydrostatic Pump

Assemble Hydrostatic Pump

Replace High-Pressure Line Center Pivot O-Rings

Disassemble and Assemble End Cover

Repair Control Valve

Displacement Control Valve with Feed Rate — Exploded View

Install Hydrostatic Pump

Remove and Install Charge Pump

Repair Charge Pump

Remove and Install Hydrostatic Control Cable

Adjust Hydrostatic Control Linkage

Adjust Displacement Control Valve Neutral

Start-Up Procedure After Hydrostatic System Repair

Group 20: Cam Lobe Motor

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Flushing Cam Lobe Motors

Remove Cam Lobe Motor

Install Cam Lobe Motor

Remove and Install Cam Lobe Motor Control Valve

Disassemble and Assemble Cam Lobe Motor Control Valve

Remove and Install Steering Yoke

Disassemble and Assemble Pivot Pins, Bushings, and Seals

Remove and Install Solenoid Valve and Valve Block

Remove and Install Displacement Control Valve

Remove and Install Cam and Piston Carrier

Remove and Install Stack Valve Seals

Remove and Install Axle Bearings and Seals

Group 25: HILLMASTER II

HILLMASTER II Rocker Assembly—RH Side

HILLMASTER II Rocker Assembly—LH Side

Section 60: Power Steering and Brakes

Group 05: Steering

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove Steering Valve

Steering Valve

Disassemble Steering Valve

Assemble Steering Valve

Install Steering Valve

Steering Column Components (Upper)

Steering Column Components (Lower)

Disassemble And Assemble Steering Column

Replace Telescoping Shaft Bearings

Remove and Install Steering Cylinder

Repair Steering Cylinder

Toe-In Adjustment

Remove and Install Steering Tie Rod

Remove and Install Rear Spindle Assembly—Non-Powered Heavy Duty

Disassemble and Assemble Rear Spindle Assembly—Non-Powered Heavy Duty

Remove and Install Rear Axle Pivot Bushing

Rear Axle Adjustment

Group 10: Brakes

Service Equipment and Tools

Other Material

Specifications

Remove Brake Drum

Remove Brake Shoe—Heavy Duty

Repair Brakes—Heavy Duty

Assemble Brakes—Heavy Duty

Install Brake Drum

Remove and Install Master Cylinder

Disassemble and Assemble Master Cylinder (Double Bleed Screw)

Adjusting Master Cylinder

Bleeding Brake System—Double Bleed Screw

Remove and Install Slave Cylinders

Disassemble and Assemble Slave Cylinder

Disassemble and Assemble Brake Pedals

Disassemble and Assemble Parking Brake Pedal

Adjust Park Brake Pedal

Group 15: Trailer Hitch

Remove Hitch

Section 70: Hydraulic Repair

Group 05: Hydraulic Reservoir

Service Equipment and Tools

Specifications

Remove and Install Reservoir

Flushing the Hydraulic System

Flushing the Reel/Belt Pickup Drive System

Start-Up Procedure After Hydrostatic System Repair

Group 10: Hydraulic Pumps

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Remove Main Hydraulic Pump

Marking Hydraulic Pump

Disassembling Hydraulic Pump

Replace Seal

Installing Gasket and Support

Triple Hydraulic Pump

Assembling Hydraulic Pump

Install Main Hydraulic Pump

Reel/Belt Pickup Pump

Remove Chaff Spreader Pump

Chaff Spreader Pump

Disassemble Chaff Spreader Pump

Assemble Chaff Spreader Pump

Install Chaff Spreader Pump

Group 15: Hydraulic Valves

Essential or Recommended Tools

Specifications

Remove and Install Hydraulic Valve Stack

Remove and Install Header Height/Ground Pressure Control Valve

Remove and Install Shut-off Valve

Solenoid Control Relief Valve Module

Solenoid Control Relief Valve Module from Serial No. 078556

Reel Raise/Lower Valve Module

Electro-Hydraulic Feeder House Reverser Valve—General Information

Disassemble Electro-Hydraulic Feeder House Reverser Valve

Threshing Cylinder Speed Valve Module

Auger Swing Valve Module

HILLMASTER II Solenoid Valve Block

Reel Fore/Aft Valve Module

HEADERTRAK Tilt Valve Module

Replacing Pilot Solenoid Assemblies

Replacing Pilot Sleeve O-Rings

Remove Reel/Belt Speed Flow Control Valve

Repair Reel/Belt Speed Flow Control Valve

Install Reel/Belt Speed Flow Control Valve

Reel Reversing Control Valve (S.N. 074502—)

Remove and Install Reel Reversing Control Valve (S.N. 074502—)

Feeder House Multi-Coupler Check Valve Identification

Disassemble, Inspect and Assemble Feeder House Multi-Coupler

Group 20: Hydraulic Cylinders

Specifications

Remove and Install Header Lift Cylinder

Disassemble and Assemble Header Lift Cylinder

Remove and Install Unloading Auger Swing Cylinder

Adjust Unloading Auger Swing Cylinder

Remove and Install Unloading Auger Drive Cylinder

Unloading Auger Drive Cylinder Adjustment

Group 21: HILLMASTER II Hydraulic Cylinder

Making a Special Tool

Other Material

Specifications

General Information

Components of HILLMASTER II Cylinder

Check Valve Components

Components of Compensating Valve

Compensating Valve Installed in Piston

Attachment of HILLMASTER II Cylinder

Group 25: Motors

Remove and Install Chaff Spreader Motor

Group 30: Accumulators

Service Equipment and Tools

Accumulator (General Information)

Checking Header Float System Accumulator

Accumulator Precharge Pressure

Section 80: Separator Shell

Group 05: Gull Wing Doors

Remove and Install Gull Wing

Group 10: Rear Hood WTS

Specifications

Remove and Install Lower Hood Panels

Remove and Install Rear Hood

Group 15: Rear Hood CTS

Specifications

Remove and Install Lower Hood Panels

Remove and Install Rear Hood

Section 90: Operator's Station Repair

Group 05: Air Conditioning System (R134a)

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Discharge and Recovery of Air Conditioning Refrigerant

Remove and Install Compressor

Test Volumetric Efficiency

Test Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Disassemble, Inspect, and Assemble Compressor

Remove and Install Compressor Relief Valve

Flush Air Conditioning System

Purge Air Conditioning System

Evacuate Air Conditioning System

Compressor Oil Information

Determine Correct Oil Charge

Check Refrigerant Oil Charge

Charge Air Conditioning System

Leak Testing Procedure

Group 10: System Components

Essential or Recommended Tools

Other Material

Remove and Install Receiver/Dryer

Replace Blower Motor

Replace Recirculator Motor Drive Module

Replace Heater Control Valve

Remove Condenser

Repair Condenser

Install Condenser

Replace Evaporator

Remove and Install Evaporator Temperature Sensor

Replace Low Pressure Switch

Replace High Pressure Switch

Replace Air Temperature Sensors

Group 15: Cab

Specifications

Remove and Install Cab Windshield

Remove Cab

Install Cab

Replace Rear Window

Remove and Install Cab Roof

Remove and Install Operator’s Seat

Remove and Install Operator Presence Switch

Operator's Seat Exploded View

Operator's Seat Air Suspension Assembly—Exploded View

Disassemble and Assemble Operator's Seat Air Suspension Assembly

Cab Door Latch Striker (S.N. 074502—)

Remove and Install Cab Door (S.N. 074502—)

Disassemble and Assemble Cab Door (S.N. 074502—)

Section 110: Feeder House Repair

Group 05: Conveyor

Other Material

Specifications

Remove and Install Feeder House

Remove and Install Conveyor Chain

Measure Conveyor Chain Wear

Removing Conveyor Chain Link

Replace Conveyor Chain Slats

Replace Conveyor Chain Wear Strips

Adjust Drum Height

Remove and Install Conveyor Drum

Conveyor Drum Exploded View—HILLMASTER II

Conveyor Drum Exploded View—Level Land and HEADERTRAK Tilt

Remove And Install Mid-Floor Assembly

Remove And Install Sub-Floor Assembly

Remove and Install Pea Kit Sub-Floor Assembly (Optional)

Feed Plate Support Exploded View

Group 10: Top Shaft and Slip Clutch

Specifications

Remove and Install Top Shaft Supports

Disassemble and Assemble Conveyor Top Shaft

Group 15: Feeder House Drives and Reverser Gear Case

Other Material

Specifications

Top Shaft Idler—Exploded View

Feeder House Countershaft and Tensioner—Exploded View

Remove and Install Reverser Gear Case

Feeder House Reverser Gear Case—Exploded View

Disassemble and Assemble Feeder House Reverser Gear Case

Remove and Install Lower Shaft

Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides

Group 20: HEADERTRAK Tilt Cylinder and Frame

Specifications

HEADERTRAK Tilt Cylinder Hoses and Fittings—Exploded View

Remove and Install HEADERTRAK Tilt Cylinder

Feeder House Shell, Wear Plates and Seal Location Drawings

Tilt Beam and Closure Plates Location Drawings

Remove and Install Tilt Frame

Remove and Install Tilt Beam

Adjust Fore-Aft Turnbuckles

Remove Fore-Aft Tilt Frame

Install Fore-Aft Tilt Frame

Group 25: HILLMASTER II Tilt Cylinder and Frame

Tilt Frame—Exploded View

Section 120: Separator WTS

Group 05: Separator Repair

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Rasp Bars

Static Balance Cylinder

Remove Threshing Cylinder

Install Threshing Cylinder

Remove Concave

Install Concave

Level Concave (Rasp Bar)

Level Concave (Spike Tooth)

Second Concave Adjustment

Concave Position Sensor and Linkage

Remove and Install Concave Adjusting Motor

Second Cylinder Exploded View

Disassemble and Assemble Second Cylinder

Remove and Install Second Cylinder

Group 10: Cylinder Drives

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Dual Range Cylinder Drive Gear Case

Dual Range Cylinder Drive Exploded View

Disassemble and Assemble Dual Range Cylinder Drive Gear Case

Remove and Install Intermediate Cylinder Drive

Repair Intermediate Cylinder Drive

Remove and Install Intermediate Cylinder Drive Support

Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave

Group 15: Straw Walkers and Crankshafts

Essential or Recommended Tools

Other Material

Specifications

All Walkers - Timing Procedure

Remove and Install Straw Walker Bearings

Remove and Install Rear Crankshaft

Remove and Install Front Crankshaft

Remove and Install Straw Walker Gear Case

Disassemble and Assemble Straw Walker Gear Case

Remove and Install Power Separator

Group 20: Straw Chopper and Chaff Spreader

Service Equipment and Tools

Other Material

Specifications

Chopper and Blades

Chopper Housing and Knife Bank

Remove Straw Chopper

Replacing Chopper Blades

Replace Knife Section

Remove and Install Rotor Bearing

Remove and Install Straw Chopper Jackshaft

Disassemble and Assemble Straw Chopper Jackshaft

Remove and Install Straw Chopper Idler Assembly

Group 25: Shoe Supply Augers, Cleaning Fan and Chaffer and Sieve Frame

Other Material

Specifications

Replace Shoe Supply Augers

Replace Shoe Supply Auger Wooden Bearings

Remove and Install Shoe Supply Auger Drive Shaft

Remove and Install Shoe Supply Auger Trough

Remove Separator Drive Jackshaft

Install Separator Drive Jackshaft

Remove and Install Cleaning Fan Drive

Fan Drive Speed Control

Remove Cleaning Fan

Install Cleaning Fan

Remove and Install Cleaning Fan Housing

Adjust Fan Speed Actuator

Remove Chaffers, Sieve and Frames

Install Chaffers, Sieve, and Frames

Remove and Install Shoe Pitman Arms

Group 30: Tailings Elevator and Augers

Disassemble Tailings Elevator and Augers

Group 35: Primary Countershaft Gear Case

Essential or Recommended Tools

Specifications

Remove and Install Primary Countershaft Gear Case

Disassemble and Assemble Primary Countershaft Gear Case

Remove and Install Primary Countershaft with Variable Sheave Assembly

Remove and Install Beater Curtain

Group 40: Header Electromagnetic Clutch

Specifications

Remove Header Electromagnetic Clutch

Disassemble and Assemble Header Electromagnetic Clutch

Install Header Electromagnetic Clutch

Section 121: Separator CTS

Group 05: Beaters

Specifications

Remove Concave

Install Concave

Serrated Beater Drive Gear Case Idler

Remove Serrated Beater Drive Gear Case

Serrated Beater Drive Gear Case

Disassemble Serrated Beater Drive Gear Case

Install Serrated Beater Drive Gear Case

Serrated Beater and Shaft

Remove Left-Hand Serrated Beater Shaft Bearing

Remove Right-Hand Serrated Beater Shaft Bearing

Remove Serrated Beater Shaft

Install Serrated Beater Shaft

Remove Beater Drive Sheave

Install Beater Drive Sheave

Remove/Install Serrated Beater Wings

Stripper Beater

Remove Stripper Beater Drive Sheave

Remove and Install Stripper Beater Shaft

Remove and Install Stripper Beater

Serrated Beater Cover

Remove Serrated Beater Cover

Remove Stripper Beater Cover

Install Stripper Beater Cover

Install Serrated Beater Cover

Remove Module Feed Assembly

Install Module Feed Assembly

Remove Serrated Beater Lower Covers

Install Serrated Beater Lower Covers

Remove and Install Beater Curtain

Group 10: Engine Gearbox to Module Drives

Engine Gearbox to Module Drives—Exploded View

Group 15: Tine Separator Module

Essential or Recommended Tools

Specifications

Rolling Out Tine Separator

Remove Tine Separator Module

Tine Separator Front Bearings and Lube Lines

Tine Separator Tubes

Remove Tine Separators

Install Tine Separators

Repair Tine Separators

Replace Tine Separator Drive Coupler

Replace Tine Separator Flow Dividers

Replace Tines

Replace Discharge Paddles

Module Frame and Covers

Discharge Beater

Discharge Beater Drive

Remove Front Feed Section Assembly

Install Front Feed Section Assembly

Module Grate Assembly

Remove Separator Grates

Install Separator Grates

Replace Grate Fingerbar

Module Crank-Out System

Remove Module Crank-Out System

Install Module Crank-Out System

Group 20: Tine Separator Gearboxes

Specifications

Module Drive Gear Case, Shaft and Coupling

Module Drive Gear Case

Remove Module Drive Gear Case

Disassemble Module Drive Gear Case

Assemble Module Drive Gear Case

Install Module Drive Gear Case

Group 25: Shoe Supply Augers, Chaffer and Sieve Frame

Shaker Pan Location Drawing

Group 30: Straw Chopper

Remove and Install Straw Chopper

Chopper and Blades

Remove and Install Rotor Bearing

Chopper Housing and Knife Bank

Replace Knife Section

Remove and Install Straw Chopper Idler Assembly

Section 130: Grain Tank and Unloading System

Group 05: Grain Tank Cross Augers

Remove and Install Grain Tank Cross Augers

Group 10: Unloading Auger System Drives

Specifications

Replacing Unloading Auger Drive Belt

Remove and Install Cross Auger Countershaft Hub and Shear Bolt

Remove Unloading Auger Drive Countershaft

Install Unloading Auger Drive Countershaft

Aligning Unloading Auger Drive

Unloading Auger Drive Cylinder Adjustment

Replacing Unloading Auger Grain Saver Door

Group 15: Vertical Unloading Auger and Lower Gear Case

Essential or Recommended Tools

Specifications

Remove Vertical Auger Lower Gear Case And Vertical Auger

Disassemble and Assemble Vertical Auger Lower Gear Case

Install Vertical Auger and Vertical Auger Lower Gear Case

Group 20: Horizontal Unloading Auger and Gear Case

Essential or Recommended Tools

Other Material

Specifications

Inspection of Horizontal Unloading Auger

17 ft. (5.18 m) and 20 ft. (6.1 m) Augers—Two-Piece

Remove Horizontal Auger

Install Horizontal Auger

Remove Horizontal Auger Gear Case

Disassemble And Assemble Horizontal Unloading Auger Gear Case

Install Horizontal Auger Gear Case

Remove Horizontal Unloading Auger Tube

Unloading Auger Elbow, Exploded View

Remove Horizontal Unloading Auger Elbow

Install Horizontal Unloading Auger Elbow

Remove Unloading Auger Charge Housing

Group 25: Clean Grain Elevator and Loading Auger Gear Case

Other Material

Specifications

Adjust Clean Grain Elevator Chain

Clean Grain Elevator Belt Replacement

Clean Grain Loading Auger, Exploded View

Replace Clean Grain Loading Auger Bearing

Remove Clean Grain Loading Auger Assembly

Remove and Install Clean Grain Elevator Gear Case

Disassemble and Assemble Clean Grain Elevator Gear Case

Remove Clean Grain Elevator

Group 30: Grain Tank and Extensions

Grain Tank Base

Grain Tank

Grain Tank Covers—8,000 and 9,000 Liters

Grain Tank Cover Seals—8,000 and 9,000 Liters

Grain Tank Cover Supports—8,000 and 9,000 Liters

Grain Tank Cover Assist Cylinders—8,000 and 9,000 Liters

Grain Tank Cover Actuator—8,000 and 9,000 Liters

Grain Tank Cover Reference—11,000 Liters

Grain Tank Covers—11,000 Liters

Grain Tank Lift Cylinder and Linkage—11,000 Liters

Section 140: Engine Gear Case and Control Valve Repair

Group 05: Engine Gear Case and Valve

Essential or Recommended Tools

Other Material

Specifications

General Information

Remove and Install Engine Gear Case

Engine Gear Case Specifications

Disassemble and Assemble Separator Drive Wet Clutch

Disassemble and Assemble Hydrostatic Gear Set

Set Gear Position

Preload Bearings

Disassemble and Assemble Straw Chopper/Unloading System

Set Separator Gear Position

Preload Bearings

Disassemble and Assemble Separator Drive

Preload Separator Drive Bearings

Set Separator Drive Gear Backlash

Disassemble and Assemble Hydrostatic Pump Drive

Preload Hydrostatic Pump Drive Bearings

Set Hydrostatic Pump Drive Gear Backlash

Disassemble and Assemble Oil Screen

Disassemble and Assemble Oil Trough

Disassemble and Assemble Dipstick Tube

Remove and Install Filter

Remove and Install Pressure Regulating Valve

Disassemble and Assemble Pressure Regulating Valve

Section 199: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFRW20—Compressor Holding Fixture

John Deere Combines 9660, 9540i, 9560i, 9580i, 9640i, 9660i, 9680i WTS, 9780i CTS Repair Service Manual (TM8090)