Complete service repair manual for John Deere 960 and 990 Hay and Forage Round Baler (Worldwide Edition), with workshop information to maintain, repair & service like professional mechanics.

John Deere Hay and Forage Round Balers Models 960 and 990 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.

TM300419 - John Deere Hay and Forage Round Balers Models 960 and 990 Technical Manual (Repair).PDF
TM300419 - John Deere Hay and Forage Round Balers Models 960 and 990 Technical Manual (Repair).EPUB

Total Pages: 768 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   Safety
      Safety Information
   General
      Serial Numbers
      Torques for Hardware
      Lubrication
      General Information
   Electrical System - Repair
      Connectors
      Sensors and Switches
      Actuators
   Power Train
      Walterscheid Powerline
      Cam-Type Cut Out Clutch
      Identification of Chains
      Chain
      Sprocket Alignment
   Braking System - Repair
      Air Brakes
      Hydraulic Brakes
      Brake Shoe and Drum
   Hydraulic System - Repair
      Bale Density Control Valve (Baler with Proportional Density Valve)
      Hydraulic Cylinders
      Gate Locking Valve
      Rotary Feeder Hydraulic Components (Baler without Precutter Device)
      Rotary Feeder Hydraulic Components (Precutter Device with 13 Knives)
      Rotary Feeder Hydraulic Components (Precutter Device with 25 Knives)
      Density Accumulator
      Pressure Gauge
   Miscellaneous
      Axle
      Side Door
      Gate Curtain
   Lubrication System - Repair
      Drive Chain Lubrication
      Automatic Greasing System
   Pickup
      Adjustment
      Repair
      Gauge Wheel
   Feeding Device
      Adjustment
      Repair
   Frame
      Crossbeam
      Gate
   Bale Chamber
      Identification of Rolls
      Baler Rolls
      Roll Scraper
      Belt Repair
      Tension Arm Repair
      Side Sheet
   Net Tying System
      Repair
   Special Tools
      Special Tools - Dealer-Fabricated
      Special Tools (Available as Spare Parts)

tm300419 - 960 and 990 Round Baler Repair -: (Worldwide Edition)

Table of Contents

Foreword

Section 05: Safety

Group 05: Safety Information

Safety Information - Summary of References

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Avoid High-Pressure Fluids

Support Machine Properly

Wear Protective Clothing

Service Machines Safely

Work in Clean Area

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Service Tires Safely

Practice Safe Maintenance

Use Proper Tools

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Safety Information - Air Brake System

Section 10: General

Group 10: Serial Numbers

Serial Numbers - Summary of References

Baler Serial Number Plate Location

Serial Number Plate Description

Group 15: Torques for Hardware

Torques for Hardware - Summary of References

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Group 20: Lubrication

Lubrication - Summary of References

High Viscosity Gear Case Oil

Grease

Multiluber Chain Oil

Group 25: General Information

General Information - Summary of References

Locking Collars for Shaft Bearings

Section 40: Electrical System - Repair

Group 05: Connectors

Connectors - Summary of References

Special Tools

Electrical Connector Handling

Disconnect the Electrical Circuit

CPC, Large MATE-N-LOK and METRIMATE Pin Type Connectors

DEUTSCH Connectors

WEATHER PACK Connectors

METRI PACK Connectors For Metri Pack connectors, 150 series

CINCH Connectors

TYCO AMP Superseal Connectors

Harness Repair (Splice Broken or Cut Wire)

Harness Repair—Splice Connector

Group 10: Sensors and Switches

Sensors and Switches - Summary of References

Sensors and Switches - Specifications

Oversize Bale Switch SB311

Gate Latch Sensors SB331 - SB332 - SB3310 - SB3311

Bale Discharging Ramp Sensor SB341 - SB343

Baler Rotation Speed Sensor SB361 - SB366

Net Feeding Sensor SB411 - SB415

B-Wrap Sensor - SB416

Twine Pulley Sensors SB421 and SB422

Drop Floor Sensor SB531

Precutter Knife Sensors SB551 - SB552

Group 15: Actuators

Actuators - Summary of References

Actuators - Other Material

Actuators - Specifications

Remove Net Tying Actuator MB411

Install Net Tying Actuator MB411

Remove and Install Twine Tying Actuator MB421

Disassemble and Assemble Actuators MB411 and MB421

Section 50: Power Train

Group 10: Walterscheid Powerline

Walterscheid Powerline - Summary of References

Walterscheid Powerline - Specifications

Remove Powerline

Install Powerline

Remove Powerline Joint Shield

Install Powerline Joint Shield

Disassembling Coupler

Assembling Coupler

Disassemble Powerline

Assemble Powerline

Exploded View of Powerline (Baler with 540 rpm Gear Case)

Exploded View of Powerline (Baler with 1000 rpm Gear Case)

Group 40: Cam-Type Cut Out Clutch

Cam-Type Cut Out Clutch - Summary of References

Cam-Type Cut Out Clutch - Other Material

Cam-Type Cut Out Clutch - Specifications

Disassemble Cam-Type Cut Out Clutch

Adjust Cam-Type Cut Out Clutch

Exploded View of Cam-Type Cut Out Clutch

Assemble Cam-Type Cut Out Clutch

Group 55: Identification of Chains

Identification of Chains - Summary of References

Baler Chain Identification

Group 60: Chain

Chains - Summary of References

Chains - Specifications

Chains - Service Equipment and Tools

Check Chain Wear

Adjust Main Drive Chain

Adjust Pickup Drive Chain

Adjust Belt Lower Drive Roll Chain

Adjust Starter Roll Drive Chain

Adjust Bale Chamber Roll Drive Chain

Adjust Rotary Feeder Drive Chain

Repair Chain

Group 65: Sprocket Alignment

Sprocket Alignment - Summary of References

Sprocket Alignment - Specifications

Check and Adjust Sprocket Alignment

Section 60: Braking System - Repair

Group 05: Air Brakes

Air Brakes - Summary of References

Air Brakes - Specifications

Preliminary Check

General Information

Drain Air Brake Reservoir

Clean Air Filters

Install Plug-in Connections

Remove Reservoir

Install Reservoir

Remove Relay Emergency Valve

Install Relay Emergency Valve

Remove Brake Cylinder (Air Brakes)

Adjust Brake Cylinder Clevis

Install Brake Cylinder (Air Brakes)

Group 10: Hydraulic Brakes

Hydraulic Brakes - Summary of References

Hydraulic Brake Cylinders

Remove Brake Cylinder (Hydraulic Brakes)

Install Brake Cylinder (Hydraulic Brakes)

Adjust Brake Cylinder (Hydraulic Brakes)

Group 15: Brake Shoe and Drum

Brake Shoe and Drum - Summary of References

Brake Shoe and Drum - Specifications

Adjust Brake Shoes (Baler with Air Brake System)

Adjust Brake Shoes (Baler with Hydraulic Brake System)

Adjust Brake Lever

Adjust Park Brake Cable

Section 70: Hydraulic System - Repair

Group 05: Bale Density Control Valve (Baler with Proportional Density Valve)

Bale Density Control Valve (Baler with Proportional Density Valve) - Summary of References

Bale Density Control Valve (Baler with Proportional Relief Valve) - Specifications

Bale Density Control Valve Safety Information (Baler with Proportional Density Valve)

General Repair Information (Baler with Proportional Density Valve)

Remove and Install Bale Density Control Valve (Baler with Proportional Density Valve)

Check Condition of Valve Seats and Poppets (Baler with Proportional Density Valve)

Setup Density Circuit Pressure (Baler with Proportional Density Valve)

Activate Density Pressure Emergency Control (Baler with Proportional Density Valve)

Deactivate Density Pressure Emergency Control (Baler with Proportional Density Valve)

Group 15: Hydraulic Cylinders

Hydraulic Cylinders - Summary of References

Hydraulic Cylinders - Other Material

Remove and Install Tension Cylinder

Remove and Install Gate Cylinder

Remove Knife Cylinder

Install Knife Cylinder

Remove Drop Floor Cylinder

Install Drop Floor Cylinder

Group 20: Gate Locking Valve

Gate Locking Valve - Summary of References

Remove and Install Gate Locking Valve

Group 25: Rotary Feeder Hydraulic Components (Baler without Precutter Device)

Rotary Feeder Hydraulic Components (Baler without Precutter Device) - Summary of References

Rotary Feeder Hydraulic Components Safety Information (Baler without Precutter Device)

Remove and Install Rotary Feeder Valve (Baler without Precutter Device)

Identification view (Baler without Precutter Device)

Group 30: Rotary Feeder Hydraulic Components (Precutter Device with 13 Knives)

Rotary Feeder Hydraulic Components (Precutter Device with 13 Knives) - Summary of References

Rotary Feeder Hydraulic Components Safety Information (Precutter Device with 13 Knives)

Remove and Install Rotary Feeder Valve (Precutter Device with 13 Knives)

Identification View (Precutter Device with 13 Knives)

Group 35: Rotary Feeder Hydraulic Components (Precutter Device with 25 Knives)

Rotary Feeder Hydraulic Components (Precutter Device with 25 Knives) - Summary of References

Rotary Feeder Hydraulic Components Safety Information (Precutter Device with 25 Knives)

Remove and Install Rotary Feeder Valve (Precutter Device with 25 Knives)

Identification View (Precutter Device with 25 Knives)

Group 40: Density Accumulator

Density Pressure Accumulator - Summary of References

Density Pressure Accumulator - Specifications

Install the FKM10474 Fill and Check Device

Remove the FKM10474 Fill and Check Device

Reduce the Accumulator Nitrogen Precharge

Increase the Accumulator Nitrogen Precharge

Group 45: Pressure Gauge

Pressure Gauge - Summary of References

Remove Pressure Gauge

Install Pressure Gauge

Section 80: Miscellaneous

Group 05: Axle

Axle - Summary of References

Axle - Specifications

Remove Axle

Install Axle

Group 25: Side Door

Side Doors - Summary of References

Side Doors - Specifications

Remove Side Door

Install Side Door

Group 30: Gate Curtain

Gate Curtain - Summary of References

Remove Gate Curtain

Install Gate Curtain

Disassemble Gate Curtain

Assemble Gate Curtain

Adjust Gate Curtain Lock

Section 85: Lubrication System - Repair

Group 05: Drive Chain Lubrication

Drive Chain Lubrication - Summary of References

Adjust Oil Flow

Bleed Chain Oiling System Pump

Adjust Brushes

Removing and Installing Hoses

Group 20: Automatic Greasing System

Automatic Greasing System - Summary of References

Exploded View of Automatic Greasing Pump

Disassemble Pump Element

Assemble Pump Element

Bleed Automatic Greasing System Pump

Section 100A: Pickup

Group 05: Adjustment

Pickup Adjustment - Summary of References

Pickup Adjustment - Specifications

Adjust Pickup Float Spring

Group 10: Repair

Pickup Repair - Summary of References

Pickup Repair - Other Material

Pickup Repair - Specifications

Remove Pickup Arm and its Bearing

Install Pickup Arm and its Bearing

Remove Pickup

Disassemble and Assemble Pickup

Install Pickup

Group 15: Gauge Wheel

Gauge Wheel - Summary of References

Gauge Wheel - Specifications

Remove Standard Gauge Wheel

Install Standard Gauge Wheel

Remove Caster Gauge Wheel

Install Caster Gauge Wheel

Remove Position Support (Standard Gauge Wheel)

Install Position Support (Standard Gauge Wheel)

Remove Position Support (Caster Gauge Wheel)

Install Position Support (Caster Gauge Wheel)

Section 100B: Feeding Device

Group 05: Adjustment

Feeding Device Adjustment - Summary of References

Feeding Device Adjustment - Specifications

Adjust Stripper

Adjust Rotary Feeder Auger Scrapers

Group 10: Repair

Feeding Device Repair - Summary of References

Feeding Device Repair - Other Material

Feeding Device Repair - Specifications

Feeding Device

Remove Rotary Feeder Bearing Housing Assembly

Install Rotary Feeder Bearing Housing Assembly

Remove Rotary Feeder

Install Rotary Feeder

Remove Drop Floor Device

Install Drop Floor Device

Section 110: Frame

Group 10: Crossbeam

Crossbeam - Summary of References

Crossbeam - Other Material

Crossbeam - Specifications

Remove Crossbeam

Disassemble Crossbeam

Exploded View of Crossbeam

Assemble Crossbeam

Install Crossbeam

Group 20: Gate

Gate - Summary of References

Gate - Other Material

Gate - Specifications

Remove Gate and its Bearing

Disassemble Gate

Assemble Gate

Install Gate and its Bearing

Adjust Gate Latch

Section 120: Bale Chamber

Group 05: Identification of Rolls

Identification of Rolls - Summary of References

Baler Roll Numbering and Belt Routing

Group 10: Baler Rolls

Baler Rolls - Summary of References

Baler Rolls - Specifications

Baler Rolls - Other Material

Remove Lower Starter Roll - No. 1

Install Lower Starter Roll - No. 1

Remove Upper Starter Roll - No. 2

Install Upper Starter Roll - No. 2

Remove Bale Chamber Roll - No. 3

Install Bale Chamber Roll - No. 3

Remove Belt Lower Drive Roll - No. 4

Install Belt Lower Drive Roll - No. 4

Remove Belt Upper Drive Roll - No. 5

Install Belt Upper Drive Roll - No. 5

Remove Tension Arm Front Roll - No. 6

Install Tension Arm Front Roll - No. 6

Remove Upper Roll - No. 7

Install Upper Roll - No. 7

Remove Tension Arm Rear Roll - No. 8

Install Tension Arm Rear Roll - No. 8

Remove Upper Roll - No. 9

Install Upper Roll - No. 9

Remove Upper Rear Roll - No. 10

Install Upper Rear Roll - No. 10

Remove Rear Gate Roll - No. 11

Install Rear Gate Roll - No. 11

Remove Belt Staggering Roll - No. 12

Install Belt Staggering Roll - No. 12

Remove Cleaning Roll - No. 13

Install Cleaning Roll - No. 13

Remove Front Gate Roll - No. 14

Install Front Gate Roll - No. 14

Remove Bale Ejecting Roll - No. 15

Install Bale Ejecting Roll - No. 15

Remove Cleaning Roll - No. 16

Install Cleaning Roll - No. 16

Remove Cleaning Roll - No. 17

Install Cleaning Roll - No. 17

Group 15: Roll Scraper

Roll Scraper - Summary of References

Roll Scraper - Specifications

Adjust Scraper of Lower Starter Roll (No. 1) (Baler up to S.N. 139999)

Adjust Scraper of Lower Starter Roll (No. 1) (Baler from S.N. 140001)

Adjust Upper Starter Roll (No. 2) Scraper

Group 20: Belt Repair

Belt Repair - Summary of References

Belt Repair - Other Material

Belt Repair - Specifications

Remove Belts

Install Belts

Adjust Belt Tracking

Group 30: Tension Arm Repair

Tension Arm Repair - Summary of References

Tension Arm Repair - Specifications

Adjust Tension Arm Spring

Adjust Take-Up Arm Spring

Remove Tension Arm Wear Plate

Install Tension Arm Wear Plate

Group 40: Side Sheet

Side Sheet - Summary of References

Remove Side Sheet

Install Side Sheet

Section 130A: Net Tying System

Group 05: Repair

Repair - Summary of References

Repair - Specifications

Exploded View of Upper Tension Arm Assembly

Exploded View of Knife and Drive Assembly

Exploded View of Duck Bill Assembly

Exploded View of Frame Assembly

Remove Net Tying System

Disassemble Net Tying System

Assemble Net Tying System

Install Net Tying System

Adjust Net Tying Counter-Knife Position

Adjust Net Tying Rubber Roll Brake

Adjust Net Feeding Sensor

Remove and Install Net Knife

Adjust Net Tying Duck Bill Position

Remove Net Wrapped Around Feed Rolls

Section 199: Special Tools

Group 05: Special Tools - Dealer-Fabricated

Special Tools - Dealer-Fabricated - Summary of References

DFEX1823A Backlash Measuring Strap

Group 10: Special Tools (Available as Spare Parts)

Special Tools (Available as Spare Parts) - Summary of References

FKM10469 - Crimping Pliers

FKM10474 - Fill and Check Device for Accumulators

JDG140 - Contact Extraction Tool

JDG143 - Contact Extraction Tool

JDG155 - Electrical Repair Tool Kit

JDG359 - Electrical Repair Tool Kit

JDG360 - DEUTSCH Crimping Pliers

JDG361 - Extraction Tool

JDG362 - Extraction Tool

JDG363 - Extraction Tool

JDG364 - Extraction Tool

JDG707 - Crimping Pliers

JDG777 - Extraction Tool

JDG783 - Crimping Pliers

JDG1725 - Extraction Tool

JDG1727 - Crimping Pliers

JDG1744 - Electrical Repair Tool Kit

JDG10202 - Terminal Crimp Tool

JDG10203 - Terminal Removal Tool

JT07115 - Pressure Test Kit

KJD10531 - Chain Wear Measuring Tool

KJD10629 - Hydraulic Circuit Pressurization Tool

John Deere Hay and Forage Round Balers Models 960 and 990 Repair Service Manual (TM300419)