9540, 9560, 9580, 9640, 9660, 9680 WTS and CWS Combines Repair TECHNICAL MANUAL 9540, 9640, 9560, 9660, 9580 and 9680 WTS and CWS Combines ‘TM4697 01NOVO1 (ENGLISCH) For complete service information also see: 9540, 9560, 9580, 9640, 9660, 9680 WTS and CWS Combines Diagnosis and Tests . ‘TM4698 Alternators and Starting Motors. . cTM77 POWERTECH' 8.1 L Diesel Engines—Base Engine . cTM86 POWERTECH 4.5L & 6.6L Diesel Engines— Base Engine. cTMt04 POWERTECH 4.5L & 6.6L Diesel Mechanical Fuel Systems cTM207 POWERTECH 8.1 L Diesel Engines—Mechanical Fuel Systems ...... CTM243 POWERTECH 4.5L & 6.8L Diesel Engines—Level 4 Electronic Fuel Systems with Bosch VP44 Pump..........+ cTM170 POWERTECH 8.1 L Diesel Engines—Level 9 Electronic Fuel Systems with Denso In-Line Pump cTM2ss John Deere Werke Zweibriicken European VersionIntroduction Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are Information is organized in groups for the various ‘components requiring service instruction. At the beginning of each group are summary listings of all Contents my Group 25—Clean Grain Elevator and Loading Auger Gear Case Group 30—Grain Tank and Extensions SECTION 140—Engine Gear Case and Control Valve Repair Group 05—Engine Gear Case and Valve SECTION 199—Dealer Fabricated Tools Group 05—Dealer Fabricated Tools| Section 10 General Contents * ase Group 05—Safety 10-05-1 Hydrostatic Drive System, Main Hydraulic ‘System and Main Engine Gear Case Oils . . .10-25-5. Group 10—Identification Number Location Transmission, Final Drives, and Drive Type Platos ia sotor “Gear Gases 10256 Combine Type Plats a “to287 Engine Sent Number “o-tot — Lubreant Storage 10287 a 104102 Atematve and Synihtc Lubvicans 10258 | ygresate Dive Unt Motor. joie | 2 Speed 4-Wheel Drive Motor. . 10-10-2, | Engine Gear Case. 10-10-3 | Transmission... 10-10-3 | Group 15—Specifications | Operating Speeds «10-15-17 | Ground Speces “house | Tuming Redus “toss Specifications - 9540 Combines : 10-156 Specifications - 9560, 9580, 9640, 9660, 9680 Combines 1045-7 Dimensions 50-15-9 Dimension Reference Points. . 10-15-10 Metric Bolt and Cap Screw Torque Values . ..10-15-11 Unified Inch Bolt and Cap Screw Torque Values 10-15-12 ©-Fing Boss Fitting Torque Chart 10-15-13 Flat Face O-Ring Seal Fiting Torque Chart 10-15-14 ‘SAE Four Bolt Flange Fitting Torque Chart. 10-15-15 Prevent Hydraulic System Contamination... 10-15-16 | Check Oil Lines and Fittings 10-15-17 Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems = 10-15-18 Group 20—Tune Up and Adjustment | Tune-Up and Adjustment 1020-4 Gare and Maintenance of Belts 10-202 Defective Belts 10-20-4 | Group 25—Fuels and Lubricants | Diesel Fuel 10-2541 | Diesel Engine Coolant 10-25-2 | Storing Fuel. . 10-252 | Supplemental Coolant Additives: 10-25-3, | Liquid Coolant Conditioner 10-253, | Diesel Engine Oil 10-25-4 | 714697 (01NOVOI) 10-1 WTS and CWS Combines Repair PNetContents | M4697 (O1NOVO1) “10-2 WTS and CWS Combines Repair exe| Recognize Safety Information | his isa stealer symbol. When you se is symbol on your mative ernie manus be alt to he oor persona uy Follow recommended precautions and safe operating practices, Understand Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identities the most serious hazards. DANGER or WARNING safely signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manwal AWARNING ACAUTION Handle Fluids Safely—Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris, Do not store oily rags; they can ignite and burn spontaneously. ‘TM4697 (01NOVO1) 10-05-1 WTS and CWS Combines Repair Perl Safety | E Prevent Battery Explosions | Keep sparks, lighted matches, and open flame away from | the top of battery. Battery gas can explode. Never check battery charge by placing a metal object, across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm | battery to 16°C (60°F) Prepare for Emergencies Be prepared i a fire stars, Keep a first aid kt and fre extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. TM4697 (01NOVO1) 10-05-2 - WTS and CWS Combines Repair exeSafety Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added, Avoiding spilling oF dripping electrolyte, Use proper jump start procedure, It you spill acid on yourself 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3, Flush your eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed: 41. Do not induce vomiting Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately. ‘T™M4697 (01NOVO1) 10-05-3 WTS and CWS Combines Repair PASSSafety Avoid High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before ? disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands ‘and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A, Park Machine Safely Botore working on the machine: * Lower all equipment to the ground, * Stop the engine and remove the key. * Disconnect the battery ground strap. + Hang a "DO NOT OPERATE" tag in operator station. WTS and CWS Combines Repair PNetO Twaeg7 (O1NOVO1) 10-05-4Safety | | | Support Machine Properly a ‘Always lower the attachment or implement to the ground | before you work on the machine. If the work requires that | | the machine or attachment be lied, provide secure | suppor for them. If left in a raised postion, hydraulically | supported devices can sete or leak down, a Do not support the machine on cinder blacks, hollow tiles, or props that may crumble under continuous load. Do not ‘work under a machine that is supported solely by a jack Follow recommended procedures in this manual. When implements or attachments are used with a machine, always follow safety precautions listed in the | implement or attachment operator's manual, pxiowen —ip-efeenn-11 Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment ‘or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Work in Clean Area e | Bett staring a jo | # Clean work area and machine + Make sure you have all necessary tools to do your job Al © Have the right parts on hand. Ez} Read all instructions thoroughly; do not attempt g shortcuts. 5 | ; l a) ‘Twa697 (O1NOVOH) 10-05-5 WTS and GWS Combines Repair PNettSafety Service Machines Safely Tie og hal behind your ead Dont wear a nec, | Eeeh bese ang? r tacence eter er esc ee foci tahegr ume cM nen er dete cough coves nun uk roe Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. Work In Ventilated Area necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe | | extension, It you do not have an exhaust pipe extension, open the doors and get outside air into the area | llluminate Work Area Safely lluminate your work area adequately but safely. Use a | portable safety light for working inside or under the | machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite ay spilled fuel or oil, | Replace Safety Signs Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement. M4697 (01NOVOT) 10-05-6 WTS and CWS Combines Repair Piet?| Safety | Use Proper Lifting Equipment | Liting heavy components incorrectly can cause severe injury or machine damage. | Follow recommended procedure for removal and | instalation of components in the manual. Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe bums to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. TM4697 (01NOVO1) ~-10-05-7 WTS and CWS Combines Repair PNet3| Satety | Er Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating ‘+ Remove paint a minimum of 76 mm (3 in.) from area to be affected by heating | « ityou sand or grind paint, avoid breathing the dust | Wear an approved respirator. | + ttyou use solvent or paint stripper, remove stripper with | soap and water before welding, Remove solvent or | paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating Do not use a chlorinated solvent in areas where welding will take place, Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly eee a Use tools appropriate to the work, Makeshift tools and | procedures can create salely hazards Use power tools only to loosen threaded parts and | fasteners. | For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. ‘TM4697 (01NOVO1) 7 10-05-8 WTS and CWS Combines Repair Ph| Safety | | Practice Safe Maintenance i Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while itis moving. Keep hands, feet , and clothing from controls to relieve pressure. Lower equipment to the (ground. Stop the engine, Remove the key. Allow machine to cool, power-driven parts. Disengage all power and operate ‘Securely support any machine elements that must be raised for service work. Keep all parts in good condition and properly installed. Fix damage immediately. Replace wom or broken parts. Remove any buildup of grease, cil, or debris. (On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine. On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine, ‘TM4697 (01NOVO1) 10-05-9 WTS and CWS Combines Repair PNeIS.I Safety E Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, fters, and batteries. | Use leakproot containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. | | Do not pour waste onto the ground, down a drain, or into any water source, | Air conditioning refrigerants escaping into the air can damage the Earth's atmosphere. Government regulations | may requ a certtied air conditioning service center to recover and recycle used air conditioning refrigerants. | Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, of from your John Deere dealer. Avoid Harmful Asbestos Dust | Avoid breathing dust that may be generated when | handling components containing asbestos fibers. Inhaled | asbestos fibers may cause lung cancer. ‘Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as. airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area, ‘TM4697 (01NOVO1) 7 10-05-10 WTS and CWS Combines Repair PNeI6Safety Service Tires Safely a Explosive separation of a tire and rim parts can cause serious injury or death, Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate | the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel, | When inflating tires, use a clip-on chuck and extension | tes tengenagh obey sd oes and | NOT in front of or over the tire assembly. Use a safety cage if available, Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts. 8 Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing, Wear a suitable hearing protective device such as earmufis or earplugs to protect against objectionable or uncomfortable loud noises. Live With Safety Before retuming machine to customer, make sure machine is functioning properly, especially the safety | systems, Install all guards and shields. TM4697 (01NOVO1) 10-05-11 WTS and CWS Combines Repair aSafety Tm4697 (O1NOVO1) 10-05-12 WTS and CWS Combines Repair PcieGroup 10 | Identification Number Location Type Plates Serial numbers identifying combine harvester components or assemblies are stamped on components or factory serial number plates. These numbers and letters are required when ordering parts or components for the combine harvester. To ensure that you always have these numbers at hand ‘enter the appropriate serial numbers in the spaces provided in each illustration. Combine Type Plate ‘A—Produet Identification Number countries only) Everton (Gartain counties oly) FoEngine Power G—Abeorption Cootcent HCFrench Homologation Purpose Only ‘permisibia rawr Load KPermisible Teller Loa (Permissible Rar Axo Load c M—Permi Front Axle Load aa | Cerise Tot! Weight, Engine Serial Number Located on rear side of engine, next to the ol filter. L TM4697 (01NOVO1) 10-10-1 WTS and CWS Combines RepairIdentification Number Location E Hydrostatic Drive Unit Pump Located on the side of the pump section Hydrostatic Drive Unit Motor Located on top of the motor section. is e 2 Speed 4-Wheel Drive Motor Located on top of motor. Tw4697 (01NOVOT) : 10-10-2 WTS and CWS Combines Repair pN=20Identification Number Location Engine Gear Case | Located on the back side. | | Transmission | | | Located on the side of the transmission, M4697 (01NOVO1) 10-10-3 WTS and GWS Combines Repair Pneas‘TM4697 (01NOVOT} Identification Number Location 10-10-4 "WTS and OWS Combines Repair PNa2e| Group 15 | Specifications | Operating Speeds e | Speeds shown are average and can vary from machine to | machine. Speeds are rated at high idle with separator | engaged no oa \ | | | Twaea7 (@INOVO) 1015-4 WAS and OWS Gombines Repair PNe23Specifications Engine: Siow tale ‘9540 (1900 rem) Slow ele 9560, 9580_ 9640, 9660, 9680 (1200 em) Wid Sreed 9500 1850 em) | Mid Speed '9560_9580_ 9640, 9660, 9680 (1680 rpm) | ast cle 9540 (2550 rpm) Fast ele 9560” 9580 9640, 9660, 0880 (2340 rpm) Rated Speed 9540 (2300 rpm) I Rated Speed (9560 9640. $580, 9660, 8660 (2100 rpm) | Separator Drive Shaft Speed 1546 rem Power Separator Speed _ — 150 rom | Main Countershatt Speed _ 1586 1m Cylinder Spee ~ ‘Standard Range (250-950 9m) | 7 Towa Range | 200-75 rp) (656850 om) Feeder House Lower Shaft: = a [ Fixed Speed 520 ram | Secondary Countershafts 590 fom | Cleaning Fi aaa = o 1 _ Standard 750-1600 7 Clean Grain Elevator 400 rom | Tailings Elevator _ 430 rom [Shoe Crankshaft - 260 rom | | Straw Walkers ae = 180 rom. | Unloading Auger Countershaft _ 1060 5m Loading Auger | 9540, 9640, 9860 and 9560 390 15m Testa — [shen [Few ane (aos on a naw = (@20- pm) | ‘Verical and Horizontal Unioading Augers | Verioal High [0 om 1 ‘Wertcal Low 1260 rom | Horizontal High [408 wom = _| Hoenn tow 320m Fine Cut Saw Chopper 3200 19m (Optional Gam 2850 and 1700 rpm ‘Straw Spreader Shaft 255 rpm {Shoe Grain Supply Augers Shatt 405 rpm ‘TM4697 (01NOVO1) 10-15-2 WTS and CWS Combines Repair PNeeeSpecifications | Ground Speeds NOTE: Speeds shown are for combines equipped with 480/80R26 Re rear tres I I ‘Speed in Ken (mph) | | Front Tire 2wo AWD Speed | First Gear ‘Second Gear ‘Third Gear | Range x | 6.7 (4.2) 12.5 (7.8 20 (12.4) | 2081-92 160R | 161 (1097 250(1557 | 31.5 (196) | tow 4800) 7a ap 80.60; 82617 876.47 1096.5" High 5785) 24 or 121 (75) 113 7.0" 137 @5y 171 09) | x 68 (42) 126 (78 20 (124. 1 ‘800/65 R32 172AB 16.2 (10.1)° 25.0 (15.5)" 316 (196) | Low 48 (30) 8015.0" | 8764" 109160) 1 High S788) oa 6a 121 (75) | 413707 137 5) | 474 (06 x ] 873) 2578 20 (1247 eons2 167 AB 162 100) 250 (155) | 3181195 | low 4200) 7 aap 8060; 220647 | 8764) 10963) Hh 5785) 24 er 121 (78) | 113 (oy 137 (85) | [1721 G06 I x 67 (42) T2508 20 (12.4 || 2est-se 16°R | 160 100" 250155" | sro nea" | Low 2880 7a (aa) 80 60: 8215.) 87.64) | | | | ros (ear [Al except Spain and ay [Spain and tay On [Seermany [Al excep! Germany and Spain | | Seain | ‘TM4697 (01NOVO1) Contin on net page 10-15-3 | cuvsessoosn asszeserei2 | WTS and CWS Combines Repair PNoesSpecifications a Sood a Kv i) Front Tire aw ‘4WD Speed | First Gear ]Second Gear | Third Gear navee rs area eager Bore | 11.2 (7.0) 13.6 (8.5) * 7 ii fose | orem wearin [a0 aeay 1 (850/75R32 167 AB : 16.0 (10 | 28.0 15.5)" | | Sova wr 7860 Tear 20.69) an erew | [10.9 (6.87 Ter ae cane ‘easy | Mort Hews: i i tree || | x 6.8 (4.2) 12.6 (7.81 20 (12.4 | esas 17048 teeon sacs sa tiear iw w380 Teen? 3960, | ele) eres | . | | 109 (6.8) | a aa wea e178 1 Tsu res | : ii ttowr | x 68 (42) 12.6 (7.8) 20 (124) || ecorsnse res. | wearer | asvusse | 31.7 (19.6) + oe wom aaa 2060; [ei eee | taser | T High 57 (35) 9.4 (5.8) 12.1 (7.55 | 11.3 (7.0) [13.7 5)" : Hater “All except Spain and tly _ | | [Spain ana ay Onis | [eeermany 2 = | [Ail except Germany and Spain ‘Svan _ 7 = uoressomouon -spossero109 ‘TM4697 (01NOVO1) 10-15-4 WTS and CWS Combines Repair PN=26Specifications Turning Radius | ‘Combine Model [Rear Wea Tea with ‘Turning Radius (9540, 9560 and 9580 [sam (ton 2iny 7.4 m (24 2 in) |[9540, 9660 ana 9680 36 mitt f 10in) 74m 24 Zin) ‘TM4697 (01NOVOt) 10-15-5 WTS and CWS Combines Repair PNe2?Spesitications E- ications - 9540 Combines Traine This = Tebow | | te soso | | Type | siceyinder, in ne, vale-invhead, | | ____| sess turbochargea Brake Horsepower ® = | 9s40— 152 KW (206 hp) | Displacement {6.8L (414 cu, in) Bore and Stoke: = : 107 x 110 mm (4.20 x 499 in) Fg Oren — 153624 fe Carr iy Type wih Stay Elona | Tremosaty Too) ee 10) | evict Gye Ta regeve pound wh 120 arp amar Transmission: : three speeds = Brakes: ‘hydraulic shoe: _ liner Taner op ba io Conca near ‘a osen bar [eter [Humbe of wines 5 Beater Grate Tipe cr ber opal sie Narber al gale bas 7 | Finger Ber i Tedaane | Separator Tea wake | [Seow wana Tener | | nial kare SS A Power Separator: Finger Pattern = 20 retractable, in-line Grain Tank: Capacity = 7.500. (213 bu) F [Average Unloading Rate ae [4200 Limi (120 busin) Wei [ess header (bse equsrei cna Gor Conon 10700 ky @3566 1) Capac: Fushi 700185 gl) | | Cooting system (with heater) 36 L (38 at) | Ege rantcas (wih ite) 1891 (20 | [rarariesion ost Hoa | Te! oes (acy estea) | I Feeder Howse Revere’ Goa Gases cet ea) Pray Couteshat Goat Case [2c es pp ] z Beat Stow War Drive Ger Case fron 802) | Dior Range Cynder Dive Gear Case tte@) | ai: e 16 L U7 aH t aeLaw | I ‘el yeonaie Reson Tarue6 an ‘TM4697 (01NOVOT) |_| The nai rating on the engine emissions cariicate label species the gross engine MpIKW, which & ywhael power without fan, In most applications this wil not be the same rating as advertised vehicie MpvkW rating”. 10-15-6 Lcuossrsowrass —inssseroi WTS and CWS Combines Repair PN=2eSpecifications Specifications - 9560, 9580, 9640, 9660, 9680 Combines Engine: Make: ‘ohn Dears Modol sOBtHZ, Type ‘sicayinder, in ine, valvesn-head, I ase turbocharged Brake Horsopower* "9560— 175 KW (288 Rp) with 200 KW | (272 hp) boost | 19880, 9640— 200 KW (272 np) with | 225 KW (306 fp) boost | '9660— 222 KW (302 hp) wih 247 KW (836 hp} boost '9680— 247 KiV (386 np) with 272 KW (370 hp) boost Displacement 8.4L (499 cu. in) Bore and Stroke: 116 x 129 mm (4.56 x 5.08 in) Firing Order yS8624 Dry Type with Salty Element Thermostats (Two) 82° (180°F) Electrical System: 12 vot, negative ground with 120 amp atemator Transmit: hae speeds Brake [vera soe yin Norbert % Concave: Tee Bopen bar Beater umber of wins é Beater Grate “pe oan ba Toe in cae Number ofa bas 10 (Finger Ber: Tipe aust Sepertor: Tipe saw wakes | [Saw wate Tipe Universal | Nba of waar (560, 980) 5 urbe of waar (9640, 060, 9680) € | Power Soparioe Finger Pairs 3560 and 9500 | | Borer, tine | 640, 9680, and 9680 | 2a evactabe, nine [rain Tonk Capac 0550 7500-213) i Capacity (9500) 000227 bu) I Capcty (640) 0001 227 bu) | I anacy (550) £00 L255 bu) Capac (680) 140001 (92 Bu) ‘Average Unloading Fate “4.200 Limi. (120 bain) Weight: Less header (base equipment on a Gom Combine) 11,230 kg (24,762 ib) Twi4697 (01NOVOT) |apotcatios this wil not be the same rating as adverbsed venice NpkW rang” Contin on nt ee 10-15-7 eto ang nese amas catia! peste eg ene SRW, Wel owe! wet Ta wo | WTS and CWS Combines Repair PNe2oSpecifications Capacities: | Fuel Tank 700 L (185 gal) { Cooiing system (with heater) (9580, 9880, 9640) 404 (42. qt) Cooling system (with neater) (9660, 9680) [ast 8. at Engine crankcase (with fier) 2851 0 a) Transmission 361 (tog) Final Drves (each) asl eq Feeder House Reverser Gear Case: [ost @py FH Reverser HiCap (wioooler) 3st 74 pi) Primary Countershatt Gear Case 12 ela ph BeaterSraw Waker Drive Gear Case 400 2c (¥4 02) ‘Dual Range Cyinder Orive Gear Case iatea) | Engine Gear Case 7 secur an Loading Auger Gear Case _ setae Hysraulerysrostate Reservoir = 34. (6 a M4697 (01NOVOT) 10-15-8 ouossssennsoe -tsosserog WTS and CWS Combines Repair pSpecifications | Dimensions eer 19540, 8550, 8590, 9680, 9660 ana 8600 alin ele wih LAME | D 3960 rm (295) W162 mm 7 8575 mm (9 8S) W518 mm (17 A) Unloading Unioeding Auger ‘gor : 895 mm (3215 1) wA200 mm OF 9600 men G2 AS) W200 mm (20 A) Unloading Unicedng Auger Auger c 2450 mm @7 Rein) 8525 mm GAH nd | ° 9500 mm (29° 10m) 140 me 20 1 n) E 3040 mm (12 Tin) 3780 mm (125 i) F 3925 mm (129m) [4000 men (9.01) | @ 615 mm @ Rin) [500 mm @hOin) H 3770 mm (12 ft 4 in.) | 3800 mm (12 #5 in) } 1 4200 me (13 ft 8 in.) with 6096 mm (20 ft) |] 4200 mm (13 118 in.) with 6096 mm (20 ty _ Unlosing Auger Unloading Augor [ 4040 me (13 19m) WST@ mm 7 FY 4040 mm (19 9 9m) WTB mm (47) Unoadng Unloading Auger Auger 3820 mm (32 89m) w S182 mm (17 A) Unloading K Unloading Auger Auger 4070 mm (1314) w4200 mm (20) 4070 mm (1994 in) wie200 mm 20) Unloasng : Unioding Avgen ‘ager u 9655 mm (1117 fn) WHO x BORO Tro ___| S655 mm (1 A 71n) wO x60 ROD Te _ 23774 mm (125 mn) w/00 x 5 RSA Tre 3774 mm (1285 in) W800 x 65 R2 To "Pear eis can be auto o various with | 3600 mm (129i) w BIB mM G7 | HILLMASTER Is a trademark of Deere & Company voter mreea sexo | TM4697 (01NOVO1) 10-15-9 WTS and CWS Combines Repair A 1Specifications E Dimension Reference Points | | ‘TM4697 (01NOVO1) 10-15-10 WTS and CWS Combines Repair Nesel Specitications | Metric Bolt and Cap Screw Torque Values OQ = 709) a | | eS ae = 0 @ 3 HO © | QE) ; elt O} : Top. Property Class ard Head Markings: Botom, Propet Class and Nut Markings [ =n Gass a0r8@ | Oise oa Gise 28 | [Size abricatea [ryt | Lubricated | Dn? | Lubricatew? | Dry®™ | Lubricate: | Oy | | ners) nomi) | “mts | nbe)_| Nene) Nemtet)_| Hee) Nem) 6 4705) | 66a | 066 | 1565 | 1905 | 151022 | 1550008) | 195045) || Me 115165) | 1asiio7 | ace) | 280s) | seass) | ames | s7e7s) | 4708) M10 Bat) agin | 43 (2) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70) wi 40(@5) | 5019) | 75068) | 95:70) | ¥10(@0)_| 140 (105) | 1900) | 165 (120) | ta [63 46) 8059) | 120(88)_ | 150 (110) [175 (130) | 220165) | 205 150) | 260 (190) | Mie [400 (7a) [425 (92) [too ct4ay | 240175) | 275 (200) | 350 (255) | 320295) | 400 (900) | Mi “a5 100) | 170,125) | 268 (198) | 390 @4s) | _a75.a7s) | 475 (050) | 440 205) | "560 (410) wa) ‘90 40) | 245 160) | 75 (275) | 476,660) | 590,680) | 675 (600) | 625 460) | 790 (580) M2 [265 195) | “ae0,24s) | sio,e7s | 650 a0) [725 635) | 920 (680) | 650,625) | 1080 (00) os 20,245) | 425 (215) | 650,480) | a20-1600) | 920,680) | 1460 650) | 1080 (@00) | 1250 (1000) zr 490 (960)_| 625,460) | 250 700) | 1200 (685)_| 1980 (1000) | +700 (1250) | v580 (160) | 2000 (1475) [so 1650 1490) | 660-625) | 1290 (950) | 1690 (1200) | 1850 (950) | 2300 1700) | 2140-1880) | 2700 (2000) [ss 900 (688) | 1150 @80)_| 1750 (1300) | 2a00 (1625) | 25001850) | 160 2028) | 2000-0150) | 9700 2780) 5 1180 (@50)_[ +480 (1075) | 2250 1680) | e850 2100) | 3200 (2350) | 4050 (3000) | 9750 2770) | 4780 (500) [--tubrcated means coated with a iubricart Such 9 engine ol or lasteners with phosphate and ol coatings [007 means plain or zine plated without any lubrication, || DO NOT use these values ia diferent torque value or iohtening | procedure is given for a specfic application. Torque values ited ara for general uso ony. Check tightness of fasteners periodical. ‘Shear bolts are designes to fa under predetermined loads. Always, replace shear bolts wih identical property cass, Fasteners should bo replaced with the game or higher property clas, It higher property clas fasteners aro used, thase shoud only be lightened to the strength ofthe original ‘TM4697 (O1NOVO1) 10-15-11 Make sure fastener threads are clean and that you propery stat thread engagement. This wil prevent them trom faling when tightening, Tighton plastic inser or crimped stee-type lock nuts to approximately 50 percent of the dry torque shown inthe chart, applied tothe aut, ‘not to the bolt head. Tighten toothed or seratadtype lock nuts tothe full torque value, oxronee -worosre | WTS and CWS Combines Repair PN=ssSpecifications E Unified Inch Bolt and Cap Screw Torque Values Vor2” roma une erserma Top, SAE Grade and Head Markings: Bottom, SAE Grade and Not Markings (00 NOT use these values i a diferent torque value or tightening procedure is glven fora specic apptcation. Torque values listed are for general use only. Check tghtness of fasteners perodially ‘Shear bots are designed to fall under predetermined load. Always replace shear bolls wit identical grade Feastoners should be replaced withthe same or higher grade. i bigher grade fasteners are used, these shoule ony be tightened 10 the strength ofthe orignal TM4697 (01NOVOT) 10-15-12 ‘Make sure fastener threads are clesn and that you propery start, thread engagement. This wil orvert them from failing when tignening Tighten laste insert or crimped steolype lock nuts to approximately 50 percent ofthe cry torque shown inthe chart, apelid to the nut, otto the bolt ead, Tighten toathed or serratet-type lock nuts to the full toque value Grade 1 (No Mark) T Grade 2" (No Mark) Grade 5, 5.1 or 5.2 | Grade 8 or 8.2 { Sie Tabricatee | Dry’ Lubrieateg™ | Ory” | Lubricate On Nem) | Nest) | Remon) Nem(t)_|Nemtby nent) | ie 3e@8 | 470s) | 64a | 7568 | osm | @ | 105; | 171128 | [ane 7787 | sez) ee) | wesc) | Testes) | a 195) | 2005) | 500] | 38 73510) | W750 | ze | ors@n | ose | «mes | «ce | cous) || 7H ze) | 28.008) | a6) | aa@esy | sen | 702 | 0065) | 100) | | 12 seas) | a2 | 830) | are) | e569) | 10 @o | 20s | 1550115) || ie We G55) | 60145) | 7666) | 95.70) | vas eal | ass 1H) | 175,99" | 220068) || | [58 67 (49) | 85 163), 105 (77) 135 (100) 170 (125) 215 (160) | 240 (175) 305 (225) | | ne 120,68) | 160,110) | 190 (140) | 240175) | 000220) | 300 200) | «25 15) _| 540 00) || 78 790 (40) | 2401176) | 180140) | a40 175) | 490 @60) | 618455) | e600) "| £70,640) 1 245.10) | 96065) | 295,10) | 050265) | 790,640) | 070 680) | 190.760) | 1900 960) 18 400 800) | 510,675) | 400 00) | 510,475) | 910/670) | 1150 (850) | 1480 (1075) | 1680 (1350) [ae ‘70 (420) | 725 (595) | 570,420} 5 (595) _| 1280 945) | 1690 (1200) | 2050 (1500) | 2600 (1920) 138 70 50) 98000) | 780,650) | 950 700) 7700 1280) | 2140680) | 2700 2000) | 5400 (250) [ne 260780) 1280 (90) | 80 790) [150 650) | 22501680) | 2850 er00) | 00 e650) | 4860 (250) [° cra 2 appli forex ap ec (ot hex ls) up 06h (152 mn) ng. Gade 1 apples or ex cap screws over 6. (152) long tora ober pes of bots ad stows of ny length, Lubretog meas coated wit a bran such a engia o sores wih espe and o eos "Diy means pla Fac plated witout any ibicaon, : WTS and CWS Combines Repair| Specitications f | O-Ring Boss Fitting Torque Chart | Straight Fitting 1. Inspect O-ring boss seat for drt or defects. 2. Lubricate O-ring with petroleum ally, Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3, Tighten fitting to torque value shown on chart ‘Angle Fitting | 1, Back-off lock nut (A) and back-up washer (B) ‘completely to head-end (C) of fitting, 2, Turn fitting into threaded boss until back-up washer contacts face of boss 2 3, Tum fitting head-end counterclockwise to proper index g| (maximum of one turn). 5 | 4, Hold fitting head-end with a wrench and tighten lock a | nut and back-up washer to proper torque value. e| NOTE: Do not allow hoses to twist when tightening ‘A—Lock Nut | fitings. B—Bock-Up Washer | coring | TTOROUE VALUE CHARI | | Torave | | Thread size Nem (et) | | [aes uve 2 6) | [716-20 ue o | | [—"we-o0 une 16 02) | | | [7 onet6 une 24 “yd | | (“aereune [as | | [wera une (46) i | 1-16-12 UN 102 75) | Fane uw 122 (90) | | | Trsr612 un 142 (405) | e-12UN 120) (G40) | 1.71612 UN a7, (460) | NOTE: Torque tolerance is + 10%. TM4697 (01NOVO1) 10-15-13 WTS and CWS Combines Repair PNaa5,Specifications E Flat Face O-Ring Seal Fitting Torque Chart | 1. Inspect the fitting sealing surtaces. They must be free | of dirt or defects. 2, Inspect the O-ring. It must be free of damage or defects. i 3. Lubricate O-rings and install into groove using 3 petroleum jelly to hold in place 2 4, Push Oxng into the groove with plenty of petroleum i | jelly so O-ring is not displaced during assembly. 5. Index angle fitings and tighten by hand pressing joint together to insure O-ring remains in place. 6, Tighten fiting or nut to torque value shown on the chart per dash size stamped on the fiting. Do not aliow hoses to twist when tightening fitings. FLAT FACE O-RING SEAL FITTING TORQUE. Nominal Tube OD Swivel Nut Bulkhead Nut | Thread Size | ] mm in in Nem tm tote 635 0.250 aiete 76 2 30 [as | 352 aa75 inbs6 [ae 1630 im | 270 ‘0.500 vanes [60 a7 [70 [es "388 0.625 a 18 © 31 Tze [ies 1905 0.750 | vanese | 108 75 fia Tes m2 087s [aa vaner [102 76 [25 2540 5.000 [as area |e 105 170 ws 5178 1250 20 Tiwi | 190 140 725 38:10 +.500 24 za 27 160 70 125 NOTE: Torque tolrance is +15 20% = | | TM4697 (01NOVO1) 10-15-14 WTS and CWS Combines Repair PNG| Specifications SAE Four Bolt Flange Fitting Torque Chart 1. Inspect the sealing surfaces for nicks or scratches, roughness or out-of-flat condition. Scratches cause leaks. Roughness causes seal wear. Out-of-fiat causes seal extrusion. If these defects cannot be polished out, replace the component. 2. Install the correct O-ring (and backup washer if required) into the groove using petroleum jelly to hold it in place. | 3. For spit flange: loosely assemble spit flange halves, being sure that the split is centrally located and perpendicular to the port. Hand tighten cap screws to | hold parts in place. Do not pinch O-ring 4, For single piece flange: put hydraulic line in the center of the flange and install four cap screws. With the flange centrally located on the port, hand tighten cap | screws to hold it in place. Do not pinch O-ring, 5. For both single piece flange and spit flange, be sure the components are properly positioned and cap Sorews are hand tight, Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten all cap screws within the specified limits shown in the char. | DO NOT use air wrenches. 00 NOT tighten one cap screw fully before tightening the others, DO NOT overtighten. Contin oot pg M4697 (O1NOVO1) 7 10-15-15 WTS and CWS Combines Repair Pnea?Specifications E [ GS een ove pour cine Tn ToRaTe = Torque I em ey | Terimaange | CipScewSie™ Wi) Win ax G TH6= 14 UNC 6 68 (42) [ 0) i Tioxte 6 a “Tolerance + 10%. The toques given are enough forthe given size connection with the recommended working pressure, Torques can be Increased to the maximum shown for each cap screw Sze If desited. Increasing cap seraw torque beyond this maximum wil result in flange and cap screw bending and connection failures. | "SAE Grade 5 or better cap screws wih plated haraware ‘Metie 10 | Prevent Hydraulic System Contamination IMPORTANT: Cleanliness is very important when working on the hydraulic system, | Prevent contamination by assembling the cylinders, hoses, couplers, and | valves in a clean area of the shop. Leave protective caps on the fluid openings until ready to make the connection. When charging the system, use a tractor or other source that contains clean oil, free of abrasive ‘materials. Keep couplers clean. Abrasive particles, like sand or metal fragments, can damage seals, barrels, and pistons, causing internal leakag ‘TM4697 (01NOVO1) 10-15-16 WTS and CWS Combines Repair PNeaSpecifications | Check Oil Lines and Fittings | CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. | ‘Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. Hf an accident occurs, see a doctor immediately. | Any fluid injected into the skin must be | ‘surgically removed within a few hours or gangrene may result. Doctors unfamiliar with | this type of injury may call the Deere & | ‘Company Medical Department in Moline, Illinois, | or other knowledgeable medical source. | Check all oil lines, hoses and fitings regulary for leaks or defects. Make sure all camps are in position and tight. | Make sure hoses are not twisted or touching machine parts which are moving. Replace damaged pars. IMPORTANT: ’ighten fittings as specified in torque chart. If necessary, use two wrenches to prevent hoses from twisting, bending or breaking tubing and fittings. ‘M4697 (01NOVO1) 10-15-17 WTS and CWS Combines Repair PN=39| Specifications E Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems Electrical Precautions To Take: Never disconnect the batteries while the key switch is ‘on. Why: This can cause electrical voltage spikes that can damage electronic components. Do not connect jumper cables while the key switch is ‘on. Why: This can cause electrical voltage spikes that can damage electronic components, Disconnect batteries prior to recharging {i possible). Why: Electrical loads in the combine can slow the recharging process. Battery chargers can cause electrical voltage spikes that can damage electronic ‘components, Never jump start the machine with a voltage higher than the machine is designed to operate on. Why: This can damage electronic components. Do not connect or disconnect electrical connectors while the key switch is on or the combine is running. Why: This can cause computer system errors from interrupting a computer program while itis running and electrical voltage spikes that are produced can damage electronic components, Do not apply power or ground to any component as a test unless specifically instructed to do so. Why: Connecting the wrong voltage to the wrong point of an electronic system can cause electronic component failures. When welding on the machine, make sure to connect ground lead to the parts being welded. For maximum protection, disconnect all electronic controller connectors before welding. Why: High currents associated with welding can damage wiring hamesses that are involved in the ground path. Welding can also cause electrical voltage spikes that can damage electronic. components. T4697 (01NOVO1) 10-15-18 WTS and CWS Combines Repair PNedoGroup 20 Tune Up and Adjustment Tune-Up and Adjustment General Information Before tuning up a combine engine, determine whether a tune-up will restore operating efficiency. When there is doubt, the following preliminary tests will help determine if the engine can be tuned up. If the Condition is satisfactory, proceed with the tune-up. Choose from the following procedures only those necessary to restore the combine Preliminary Engine Testing Test for engine compression (minimum readings at cranking speed). It is very important that all cylinder pressures be approximately alike. There should be less than 172 kPa (1.72 bar) (25 psi) difference between cylinder pressures. Engine Tune-Up Air Intake System: * Check system for leaks. | | Exhaust System: Cooling System: * Clean rotary screen, radiator core, air conditioning condenser and charge air cooler. ‘+ Cheok radiator cap. Inspect all hoses. Cylinder Head and Valves: '* Set valve clearance. Fuel System: Check fuel tank for water and drain off if required. Check fuel tank and lines for leaks or restrictions, Check electric fuel pump pressure. Blood fuel system. Check injection pump timing, Replace fuel fiter Replace water separator. Electrical System ‘© Clean and tighten battery cables and connections. * Check altemator bet tension. | + Check alternator output | + Check system for leaks. Check for restricted muffler + Check neutral safety start switch operation. | or exhaust pipe. + Check safety seat switch operation. | | * Check starter draw. | | Crankease Vent + Check battery voltage. | | «Inspect all wiring. | | + Check for restrictions | | | | | creas seesccreran | TM4697 (01NOVO1) 10-20-1 WTS and CWS Combines Repair PNestTune Up and Adjustment | Care and Maintenance of Belts V-belts are an important part of a machine. Their care and maintenance is important. A V-belt transmits ower by friction and a wedging action against the sheaves. Therefore, proper belt tension and the condition of the sheave side walls are of primary importance. Since the power is transmitted between the belts and the sides of the sheave, look there for signs of wear. All belts and sheaves wear with use. Normal wear can be recognized as even wear—both on the belt and the sides of the sheave. It is the unusual signs of wear to | look for and correct. When checking belts, remember that many belts reported as being defective have actually been damaged by a bad sheave, misaligned drive or some faulty mechanical component of the machine. EXAMPLES OF UNUSUAL WEAR, Base Cracking—Excessive cross cracking extending into the rubber on the base of a belt having litle or no | side wear indicates that the belt has been run a relatively short time and, therefore, must be defective. Small cracks, which are in the cover material only, do | not indicate belt failure. Ifthe side walls show substantial wear, the belt should | not be classified as being defective. Actually, the cracks in the base of the belt show that it has been ‘exposed to weather to the extent thatthe inner fabric is beginning to rot Fabric Rupture—A fabric rupture can be caused by operating a belt over badly worn sheaves, by too much | tension which forces the belt down into the grooves, or by foreign objects falling into the sheave groove while the drive is operating In cases such as this, check condition of the sheaves. Avoid prying belts onto sheaves. Cover Tear—A tear in the cover of a belt is caused by the belt accidentally coming into contact with some Part of the machine. It is no fault of the belt or its construction In many cases, such failure is due to belts running too loose, allowing them to “throw-out" centrifugally so they rub on parts of the machine. Proper belt tension would prevent this from happening, NOTE: A slight raveling of the belt covering at the splice does not indicate premature failure. Cut off the raveling if the cover peels at the fap. Slip Burn—This belt has been ruined by being operated too loose. The belt slipped under load and, when finally it grabbed, it snapped Check belt tension frequentiy. Tum drives over by hand to be sure they are free. Advise operators to lear machines of crop before stopping to avoid over loading drives when starting up again. Gouged Edge—A gouged edge in a belt is caused by either a damaged sheave or interference with some part of a machine. Check the condition of the sheaves. Be sure belt does not rub on any part of the machine while operating. Burn Due to Locked Drive—A bumed area in a belt is, an indication that the drive locked, causing the belt to, slip on the sheave. Prevent drive from locking by checking the tension of any chain drives in the drive train. Avoid overloading and plugging the machine. Never attempt to unplug a machine with power without first cleaning it out Lubricate the machine at the specified intervals to prevent bearing seizure. Worn Sides—Baaly worn sides of a belt result from long operation without enough tension. The sides will be worn and the entire circumference will be slightly burned. ‘TM4697 (01NOVOT) 10-20-2 WTS and CWS Combines Repair PreeTune Up and Adjustment } Check be tension, Alo, check sheave for incorrect a alignment. soviorse so.1serov22 ‘TM4697 (01NOVO1) 10-20-3 WTS and CWS Combines Repair PNATune Up and Adjustment Defective Belts Excessive Stretch—A belt that stretches excessively is ne that stretches beyond the tightener adjustment provided to take up normal belt stretch. If this condition ‘occurs, it wil usually develop within the warranty period Lumpy Belts—Lumpy belts usually occur and are more noticeable on variable speed drives and other high-speed belt installations. The result is excessive vibration. I belts are not relieved of tension while machine is stored, they will often cause temporary vibration upon start-up. Give them time to straighten out Intermal Cord Failure—Failure of one or more of the internal tension cords will result in the belt rolling over in the sheaves. (Cords can be broken by prying a new belt over sheaves.) Improper Length—t is possible for belts either too long ( too short to be shipped accidentally in service parts orders. Such belts would not pass the line run-in for new machines at the factory. Belt Replacement Here are a few general facts to know when replacing V-belts. Replace Matched Sets—Never replace just one belt of ‘a matched set. Never install individual belts from matched sets, Install the complete matched set only. ‘Check Condition of Sheaves—Always check the condition of all sheaves before replacing a belt. Check the sheaves for chips, cracks, bent sidewalls, rust corrosion, etc. V-belts must have @ smooth, dry surface to grip in order to deliver full power. Replace any sheaves that are found to be defective. Check Sheave Alignment—Misaligned sheaves will result in shortened belt lite, Use a straightedge or cord to check sheave alignment. ‘TMi4697 (O1NOVO1) 10-20-4 Position straightedge or cord so it touches sheaves at all points. Shafts must be parallel. Rotate each sheave a half revolution and note whether the contact of either sheave with the straightedge is disturbed. If so, it indicates a bent shaft or wobbling sheave. Belt installation ‘Always practice the following when installing new belts. 1. Before installing any new belt, move the adjustable | tightener to the position where it provides the least tension when the belt is installed. In some cases, it may be necessary to remove the tightener to install the belt. 2. Examine sheaves for chips, cracks, bent sidewalls, Tust, corrosion or other damage. 3. Check sheaves for alignment 4, Place the belt in the sheave groove by hand. IMPORTANT: Never pry or force a belt onto the sheave with screwdrivers, crowbars, wedges, etc. Damage to the belt and drive can result. Belt Tension Adjustment | All belts and sheaves wear with use. For this reason, adjustable tightener arrangements are provided in the drive to maintain the proper belt tension. More belts fail from under tension than over tension. To carry their full oad, V-belts must be kept taut so they grip the full arc of contact with the sheave. Some belts may snap in two from a crack-the-whip effect caused by operating the be't too loose. Loose belts slip, heat and burn, causing unnecessary wear and damage. WTS and CWS Combines Repair PNedd‘T4697 (O1NOVO1) Tune Up and Adjustment Belts with spring-loaded idler will frequently appear quite loose but should be tightened only as instructed in the operator's manual. However, V-belts should not be excessively tight. When belts are too tight, bearings and sheaves heat up, even though well lubricated. Too much tension stretches and weakens belts. CAUTION: Never attempt to check or adjust belts while the machine is running. Proper Belt Tension—Atter a new V-belt has been installed, adjust belt tension as follows: 1. Apply tension as instructed in the machine operator's manual or until the belt appears snug. Run the machine long enough for the belt to seat property in the grooves. NOTE: All new belts have an initial stretch. It will be necessary to adjust the tension at shorter intervals unti the belt is properly seated and the initial stretch is eliminated. 2, Stop the machine. Adjust the belt unti it has the proper tension as described in the operator's manual or use the following “slap test’. Slap the belt sharply with your hand. It should feel springy and alive. A dead, ifeless feel means the belt is too loose and should be tightened. 3. Advise owner to check belt tension as instructed in the operator's manual. Under no circumstances. should a belt be allowed to operate loose. Belt Care Balt dressing is not recommended on any belt, V- or flat, at any time. Most dressings contain chemicals which tend to soften belts. While this softening process actually does increase the friction between the belt and sheave grooves. the result is only temporary. Remove grease and oil as quickly as possible before they can penetrate deeply into the belt, causing rapid deterioration. 10-20-5 CAUTION: Do not attempt to clean the belts while the machine is running. Never use flammable cleaning solvent: Ciean bls by wiping hem with a lean coh Use a | nonvflammable cleaner or solvent to remave excessive | grease and oil, Water and a detergent soap canbe | Used, but it is not as satisfactory as a non-flammable | cleaner. | Belt Storage Proper belt storage is as important for new belts in| your parts department as its for those on the | customer's machines. | In the Shop—Store new belts as follows to keep them, factory-fresh for your customers. +. Stote belts ina clean, cool dry atmosphere. Undue shrinkage or deterioration may occur if belts are piled on damp floors or stored near radiators. | | 2. Keep belts away from sun and heat. 3. Do not place belts in bins for long periods. To do so might distort the shape of the belt 4, Do not hang belts on small pegs or nails. Heavy belts can be weakened due to distortion from such a practice, ‘On Customer's Machines—Pass along the following tips to your customers about storing belts 1. Ha belt is not to be removed, relieve belt tension by loosening the tightener adjustment. This is necessary to prevent the belt from “setting” or developing unequal stresses that might lead to early failure. | | | | | 5. Do not break matched sets. | | | | | 2. If possible, remove all belts. Thoroughly clean them | as described earlier in this article. Then store them | in a cool, clean, dry atmosphere | | WTS and CWS Combines Repair PNed5, Contin on 0 pgTune Up and Adjustment 3. Ifthe belts have been removed, coat sheave 4, Protect all movable or sliding parts of variable ‘grooves with anti-tust compound or grease prior to speed drives by lubricating them thoroughly to storage, Be sure to remove such rust preventative prevent corrosion due to moisture. before installing the belts and starting the machine. ‘Sheave grooves can also be protected with a section of discarded belt tied in place. ‘TM4697 (01NOVOT) 10-20-6 WTS and CWS Combines Repair PN=s6Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diese! fuels are blended to satisty the low temperature requirements of the geographical area in which they are marketed, Diese! fuels specitied to EN 590 or ASTM D975 are recommended, In all cases, the fuel shall meet the following properties: Cetane number of 40 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) of elevations above 1500 m (5000 tt). Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C (9°F) below the expected low temperature. Group 25 Fuels and Lubricants Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. Sulfur content: + Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred. + If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for ‘engine oll and fiter by 50%. + DO NOT use diesel fuel with sulfur content greater than 1.0%. Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification. D0 NOT mix used engine oil or any other type of lubricant with diesel fuel ‘TM4697 (O1NOVOT) 10-25-1 WTS and CWS Combines Repair PNeaFuels and Lubricants E Diesel Engine Coolant The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (34°F) The following engine coolant is preferred for service: + John Deere COOL-GARD Prediluted Coolant ‘The following engine coolant is also recommended: + John Deere COOL-GARD Coolant Concentrate in a 40 to 60% mixture of concentrate with quality water. Other low silicate ethylene glycol base coolants for heavy-duty engines may be used if they mest one of the following specifications: ‘+ ASTM D5345 (prediluted coolant) ‘+ ASTM D4985 (coolant concentrate) in a 40 to 60% mixture of concentrate with quality water Coolants meeting these specifications require use of supplemental coolant additives, formulated for | heavy-duty diesel engines, for protection against corrosion and cylinder liner erosion and pitting A 0% mixture of ethylene glycol engine coolant in | water provides freeze protection to -37°C (-34°F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations. Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives. Coolant Drain Intervals Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant after the first 3 ‘years or 3000 hours of operation. Subsequent drain intervals are determined by the coolant used for service. At each interval, drain the coolant, flush the cooling system, and refill with new coolant. When John Deere COOL-GARD is used, the drain interval may be extended to 5 years or 5000 hours of operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding supplemental coolant additive, lf COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation, Storing Fuel It there is a very slow turnover of fuel in the fuel tank or supply tank, it may be necessary to add a fuel conditioner to prevent water condensation. Contact your John Deere dealer for proper service or maintenance recommendations. WTS and CWS Combines Repair ‘TM4697 (01NOVO1) 10-25-2 PpFuels and Lubricants Supplemental Coolant Additives The concentration of coolant additives is gradually depleted during engine operation. For all recommended coolants, replenish additives between drain intervals by adding a supplemental coolant additive every 12 months or as determined necessary by coolant testing, John Deere COOLANT CONDITIONER is recommended as a supplemental coolant adcitive in John Deere engines. IMPORTANT: Do not add a supplemental coolant additive when the cooling system is drained and refilled with John Deere COOL-GARD. If other coolants are used, consult the coolant supplier land follow the manufacturer's recommendation for use ‘of supplemental coolant additives. ‘The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant, Add the manufacturer's recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount uid Coolant Conditioner John Deere Liquid Coolant Conditioner TY 16004 is recommended for wet-sleeve diesel engines not having a coolant fer option. Other conditioners may be used if it | contains non-chromate inhibitors. IMPORTANT: John Deere Liquid Coolant Conditioner does not protect against freezing. Various sizes of coolant conditioner are available from your John Deere dealer. ‘M4697 (O1NOVOT) 10-25-3 WTS and GWS Gombines Repair PNedBFuels and Lubricants range during the period between oil changes. Use oil viscosity based on the expected air temperature so'c ff} s20% = ao'c ttt 10°F | wef wwe T The following oil is preferred 7 8 Be zoicl care peer i 3 38 og woll sor | The folowing oils also recommended: a? i 3&8 ocht ar + John Deere TORO-GARD SUPREME: 40 : soc fH s4°r Other oils may be used if they meet one or more of the ol following: 5 awicHt 2% E | + API Service Classification CH-4 i * API Service Classification CG-4 LL wcll sore? + API Service Classiication CF-4 3 | ‘+ ACEA Specification ES & | ‘+ ACEA Specification E2 Multi-viscosity diesel engine oils are preferred. If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by 50%, Extended service intervals may apply when John Deere preferred engine oils are used. Consult your John Deere | dealer for more information, PLUS-50 6a registred trademark of Dear 8 Company. TORG-GARD SUPREME isa registorod trasemark of Deere & Company OKENOL te-guatooin ‘TM4697 (01NOVO1) 10-25-4 WTS and CWS Combines Repair PN=50Fuels and Lubricants | System and Main Engine Gear Case Oils NOTE: The combine comes from the factory with SAE 10W oil. If you change oil, you can use any of the oils listed below. 1. SAE 10W engine oils if they meet API Service Classification CD or CE. 2, John Deere Low Viscosity HY-GARD: Transmission/Hydraulic. 3. John Deere All Weather Hydrostatic Fluid outside of U.S.A. and Canada must meet: + Ford M2C39F specification «+ Ford M2C33G specification | Hydrostatic Drive System, Main Hydraulic a HY-GARD is registered trademark of Deore & Company. vost ross =se-7aygnrt TM4697 (01NOVO1) 10-25-5 WTS and CWS Combines Repair PuesFuels and Lubricants | Transmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger Elevator and Two-Speed Separator Drive Gear Cases John Deere API GL-5 80W90 Gear Lubricant is recommended. If other oils are used, they must meet requirements of: * API Service Classification GL-S | © Miltary Specification MIL-L-2105B g | + Military Specification MIL-L-2105C 3 & 6 SAE e5W1 ‘SAE 80W90 SAE 80W 140. | fil period, use oil of viscosity as shown in the chart. Product ] Pro. ‘Number | Description size | avy. ‘Ty6252 | BOW/90 GLS Gear Lube 16 kg pail if | (35 Ib. pail | | [reese [eowe0 Gis Geartuwe [oat i atycan [2 : e056 | B5W/140 GLs Gear Lube | 16 hg pal 1 5 (951. pai) t TrE045 | BSWHA0 GIS Gear Lobe [OAL (1) can | 12 a | i | M4697 (01NOVO1) 10-25-6 WTS and CWS Combines Repair Nas?Fuels and Lubricants Grease soe ff) 120° a Use grease based on NLGI consistency numbers and the wrofl soe ‘expected air temperature range during the service interval. a2 ale5 4 socllll cor 7 The following grease is recommended: Engg e 3 | 33228 acl oe 5 | « John Deere SD POLYUREA GREASE (TY6341) Po2is 5s | gees) wel mr EE | Other greases may be used if they meet the following: i £2e¢ 2 25 oollll wr 2 2 bes 38 + NLGI Performance Classicaton GC-L8 EPELL coclll we | | | IMPORTANT: John Deere SD POLYUREA GREASE ee le (T6341) is the required grease for the z feeder house torque sensing cams. corel core Some types of grease thickeners are orc Hl sore not compatible with others. | If grease fitting is missing, replace | immediately. Clean fittings thoroughly before using grease gun. | [Tyesar ‘Mull-Purpose, High-Temperature Extreme) | Pressure Groaso, especially Ll ‘contact applications, accquowss 117519. 26007H5 Lubricant Storage Your equipment can operate at top efficiency only Make certain that all containers are properly marked to when clean lubricants are used. identity their contents. Use clean containers to handle all lubricants Property dispose of all old containers and any residual lubricant they may contain, Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid | water and dirt accurnulation ‘TM4697 (01NOVO1) 10-25-7 WTS and CWS Combines Repair PNnSSFuels and Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual ‘Some John Deere brand coolants and lubricants may not be available in your location, Consult your John Deere dealer to obtain information and recommendations. ‘Synthetic lubricants may be used if they meet the performance requirements as shown in this manual. The temperature limits and service intervals shown in this manual apply to both conventional and synthetic cls. Re-refined base stock products may be used if the finished lubricant meets the performance requirements. | M4697 (01NOVOT) 10-25-8 WTS and CWS Combines Repair PN=Ba| Section 20 | Engine | Contents | Page | Group 05—Remove and Install En: Essential or Recommended Tools. 20-05-1 Specifications . .20-05-2 | John Deere Engine Repair... . 20-05-3 Remove Engine : 20-053 ~ | install Engine . 20-05-12 | Group 10—Lower Engine Repair | Remove and Install Engine Oil Pan Access Sheet. . . 20-10-1 | roup 15—Cooting System | Spectications seve reess BOMBA | John Deere Engine Repair 112041541 | Remove and Install Rotary Screen Drive... 20-15-2 | Remove and install Rotary Screen Idler Arm | end Sheaves vs 2OM5 4 | Remove and Install Rotary Screen - .20-15-6 | Remove and Install Radiator 20-15-7 | Test Radiator 20-18-12 | Test Radiator Cap. . wees 2015-13 | Replace Thermostat TI 204843 | Repair or Replace Water Pump, 20-16-13 | | | | | | | | | l | M4697 (01NOVO1) 20-1 WTS and CWS Combines Repair PietContents ‘TM4697 (01NOVO1) 20-2 WTS and CWS Combines Repair peeRemove and Install Engine Group 05 | Essential or Recommended Tools | NOTE: Order tools from the U.S, SERVIGEGARD™ or European Microfiche Too! Catalogs. ESSENTIAL TOOLS listed are required to pertorm the job correctly and are obtainable only from SERVICEGARD™ or European Microfiche Too! Catalogs. RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers or may be fabricated. SERVICEGARD is a trademark of Deore & Company Engine Lifting Sling... 2... Joa23 To remove and install engine t ? Liting Eye... Joes To attach engine sling TM4697 (01NOVO1) 20-05-1 WTS and CWS Combines Repair PN=S7| | Remove and Install Engine Specifications | um Messurement Speciation i 6068 Engine Weight 602 kg (1324 Ib) | 6081 Engine Weight 816 kg | (1800 Ib) Engine-to-Gear Case Cap Screws ‘Torque (340 Nem (250 bb) Front Engine Mount Cap Screws (6081 Engine) Block Cap Screws Torque 90 Nem (75 Ib-ft) | | channel Cap Screws Torque 70 Nem | (50 Ib-ft) | Front Engine Mount Cap Screws (6068 Engine) | Block Cap Screws Torque 205 Nem (150 lb-tt) ‘Channel Cap Screws Torque 70 Nem (50 lo-ft) | | | Cooling Fan Cap Screws Torque 60 Nem | (45 lett) | Radiator Hose Clamps Torque 4.5 Nem (40 Ib-in.) Charge Air Cooler Tube Clamp Nuts Torque. 11.Nem | (8 lb-ft) | | | | | = S | M4697 (01NOVOT) — 20-05-2 WTS and CWS Combines Repair PNasel nee | | John Deere Engine Repair | For complete repair information, the component technical manual (CTM) is also required. Use the component technical manual in conjunction with this manval. i [combine Engine Reterence 3 [saa 6068 [ermsow207 5 [oseo, ase a640, oes oTmas.255, g | 860 ana 3680 e L unseen oxses -t8et uno | Remove Engine 1. Disconnect negative (-) battery cable (A) from both batteries in engine compartment. Lift protective covers land remove both positive terminal clamps (B). 2, Remove all shields and brackets necessary to provide clearance for engine removal. ‘A—Negative Terminal Clamps. ‘B—Positive Terminal Clamps Batterias | | Continued on nxt page uosesscoses te essnor-t6 TM4697 (01NOVO1) 20-05-3 WTS and CWS Combines Repair PINSRemove and Install Engine | 8. Loosen clamps (A), (B) and (0), disconnect connector (©) and remove cap screw and nut (E); then remove air fiter assembly (F) ‘A—Clamp B—Clamp ‘c—Connector D—Clamp Cap Screw and Nut FoAir Filter Assembly = = = 4, Remove cap screws (A) and intake duct (B). | | Aap screw (4 used) BoIntake Duct WTS and CWS Combines Repair PN=60 wia697 (01NOVO1)Remove and Install Engine 5. Loosen clamps (A) and remove cap screw, nut (B) and charge air cooler tubes (C). 6. Remove clamp (D), loosen clamp (E) and rotate exhaust tube (F) toward left-hand side, F_Exhaust Tube ‘A—Clamp (4 used) ie ‘B—Cap Screw and Nut iS ‘C—Charge Air Cooler Tubes i | D—Clamp i E—Clamp 2 a CAUTION: Coolant may be hot. Wait until radiator is coo! before draining coolant. 7. Drain cooling system. Approximate cooling system a : ee shy Wy) ‘+ 9560, 9580 and 9640 Combines—40 L (42 at) ) CJ i eo FS Twd697 (01NOVOT) 20-055 ~~ WTS and CWS Combines Repair PRemove and Install Engine 8. Loosen clamps (A) and remove cap screw (B); then remove radiator hoses (C). 9. Remove cap screws, nuts (D) and upper fan shroud, ©. ‘A—Clamp (4 used) B—Cap Screw (C—Radliator Hose (2 used) D—Cap Serew and Nut (10 used) E—Upper Fan Shroud 10. Remove cap screws (A), cooling fan (B) and spacer ©. ‘A—Cap Screw (6 used) Cooling Fan c—Spacer 11, Remove cap screws, nuts (A) and lower fan shroud 8). ‘A—Nut (2 used) B—Lower Fan Shroud ‘TM4697 (01NOVO1) : 20-05-6 WTS and CWS Combines Repair PN=62Remove and Install Engine | 12 13, 14. 15. 16. 17. Loosen nut and jam nut (A); then remove rotary screen drive belt (B). Remove spring pin (C) and linkage (D). Rotate idler assembly upwards and secure with wire. ‘A—Nut and Jam Nut Edler Assembly Disconnect connectors (A)—(G). Loosen engine oil drain hose clamp (H) and remove hose. Disconnect ground cables (I) ‘A—Fuel Temperature Sensor Connector B_Water in Fuel Sensor Connector C-Oll Pressure Switch Connector Engine Speed Sensor Connector E—Engine Cold Start Aid Connector F_Engine Coolant Temperature Sensor Connector G—Fuel Injector Connector H-Engine Oil Drain Hose Clamp Ground Cables ‘TM4697 (01NOVO1) 20-05-7 WTS and CWS Combines Repair PNa6S| [re | 19. 20. a1 Remove and Install Engine Disconnect connectors (A)—(D) Disconnect wiring harness lead-to-altemator (E), Disconnect fuel return lines (F) and (G). |. Disconnect heater hose (H). ‘A—Fuel Rail Pressure Sensor Connector ‘BHnjector Pump Connector (C—injector Pump Connector Deinjector Pump Connector E—Wiring Harness Lead-to-Alternator Fuel Rall Return Line Ginjector Pump Fuel Return Line HHeater Hose ‘TM4697 (01NOVO1) 20-05-8 WTS and CWS Combines Repair PNaésRemove and Install Engine 22, Remove engine access cover located inside grain tank. 23. Disconnect connector (A) and wire (B). 24, Remove belt (C). NOTE: DO NOT disconnect refrigerant lines. 25. Remove cap screws (D) and move air conditioning compressor to an area clear of engine. 26. Disconnect heater hose (E). 27. Disconnect fuel tank breather line (F). 28. Disconnect inlet air temperature sensor connector, ©). 29. Disconnect wiring hamess leads to starter (H). 80. Remove starter relay cover (I) and disconnect wires (). ‘A~Alr Conditioning Compressor Connector Wire Bent Cap Screw (3 used) E—Heater Hose Fuel Tank Breather Line ‘G—inlet Air Temperature Sensor Connector H-—-Wiring Harness Lead to Starter ‘cover Wires | Canned on at eae ucts cuts vases 128 ‘M4697 (01NOVO1) 20-05-9 WTS and CWS Combines Repair NetsRemove and Install Engine A CAUTION: The approximate weight of the 6068 engine is 602 kg (1324 Ib). The approximate weight of the 6081 engine is 816 kg (1800 Ib). E By CAUTION: The only recommended method for lifting the engine is with JDG23 Lifting Sling and safety approved lilting straps. Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended Lift engine with longitudinal loading on lift sling greatly reduces brackets. 31. Connect JDG23 Lifting Sling (A) to JO244 Lifting Eyes (8) and take up slack in ift chains before removing engine mount cap screws. and lifting brackets only. Angular loading ‘A—0623 Littng Sling ing capacity of sling and Bu0244 Liting Eyes cuosassoontsee —te-asenee-1918 32, Remove cap screws and nuts (A) and (B) and cap screws (C) on both sides of the engine to remove front engine mounts (0). ‘A~Cap Serew and Nut (4 uses) B—Cap Serew and Nut (4 used) (CCap Screw (4 D—Front Engine Mount (2 used) M4697 (01NOVO1) 20-05-10 WTS and CWS Combines Repair PANE| Remove and install Engine 83. Remove cold start aid line clamp cap screw (A) 34. Remove fuel line (C). 35. Remove four dust cover-to-gear case cap screws (D). 36. Remove four gear case-to-engine cap screws (B). | BA CAUTION: Use extreme care when lifting engine and NEVER permit any part of the body to be | positioned under a load being lifted or suspended. 37. Carefully move engine away from gear case. Litt engine out of combine. 38. Repair or replace engine as necessary. (Refer to engine CTMs for repair information.) + 6068 Engine (See CTMI04) : | © 6081 Engine (See CTM86) : i cap serew : Soap Sere use) i cofotl Line D—Cap Screw (4 used) M4697 (01NOVOT) 20-05-11 WTS and GWS Combines Repair Preer| Remove and Install Engine Install Engine CAUTION: The approximate weight of the 6068 engine is 602 kg (1324 Ib). The approximate E weight of the 6081 engine is 816 kg (1800 Ib). By CAUTION: The only recommended method for lifting the engine is with JDG23 Lifting Sling and safety approved lifting straps. Use extreme = caution when lifting and NEVER permit any part (0 of the body to be positioned under an engine being lifted or suspended. | ‘&—-JD623 Lifting Sling Lift engine with longitudinal loading on lift sling B—I0244 Liting Eyes | and lifting brackets only. Angular loading | greatly reduces lifting capacity of sling and brackets. 1. Connect JDG23 Lifting Sling (A) to JD244 Lifting Eyes (8) and carefully lower engine to align with gear case. 2. Install gear case-to-engine cap screws (B) and tighten to specification Specification Engine-to-Gear Case Cap ‘Sciaws—Terque. 340 Nem (250 st) 3. Install dust cover cap screws (D). 4, Connect fuel line (C), 5. Connect cold start aid line to gear case using cap screw (A). ‘A—Cap Screw B—Cap Screw (4 used) c—Fuel Line | D—Cap Screw (4 used) omiued on non sage cuosesscontser -tecsscoone ‘M4697 (01NOVO1) 20-05-12 WTS and CWS Combines Repair PNs6sRemove and Install Engine | 6. install front engine mount (0) using cap screws (C) land cap screws and nuts (A) and (B). Tighten to specifications. | __ Front Engine Mount Cap Screws (6081 Engine}—Specification | Block Cap Serews—Torque 20 Nem | 5 bet) } channel Cap Serews—Torque 7oNem (601m Front Engine Mount Cap Screws (6068 Engine)—-Specitication Block Cap Screws—Torque 205 Nem (150 Inet) (60 o-) | | chat Cop Scome—Ter ane | 7. Remove JDG23 Lifting Sling and JD244 Litting Eyes. | ‘A—Gap Screw and Nut (4 used) B-Cap Screw and Nut (4 used) (GCap Screw (4 used) D—Front Engine Mount (2 used) ‘TM4697 (01NOVO1) 20-05-13 WTS and CWS Combines Repair PN=6oRemove and Install Engine 8. Attach air conditioning compressor using cap screws (0). 9. Install belt (C). 10. Connect wire (B) and connector (A). 11. Connect heater hose (E), fuel tank breather line (F) and inlet air temperature sensor connector (G). 12. Connect wiring harness starter leads (H), starter relay | wires (J) and install cover (I) 19. Install engine access cover with six cap screws. ‘Air Conditioning Compressor Connector B—Wire ‘c—Bett Cap Screw (3 used) E—Heater Hose F-Fuel Tank Breather Line ‘G—Inlet Air Temperature Connector Wiring Harness Startor Leads ‘cover J-Starter olay Wires ‘TM4697 (01NOVO1) 20-05-14 WTS and CWS Combines Repair PN=7ORemove and Install Engine 44, Connect fuel rail pressure sensor connector (A) and injector pump connectors (B)—(0). 18. Connect wiring hamess lead to alternator (E). 16. Connect fuel rail return line (F) and injector pump return line (G). 17. Connect heater hose (H). ‘A—Fuel Rall Pressure Sensor Connector jector Pump Connector {C—Injector Pump Connector D-injector Pump Connector 1g Harness Lead to Alternator all Return Line G—injector Pump Fuel Return Line H—Heater Hose 18. Connect connectors (A}—(G). 19. Connect engine oil drain hose using hose clamp (H). 20. Connect ground cables (\). ‘A—Fuel Temperature Sensor Connector ‘B—Water in Fuel Sensor Connector (C—Oil Pressure Switch Connector (D—Engine Speed Sensor Connector E_Engine Cold Start Aid Connector F—Engine Coolant Temperature Sensor Connector ‘G—Fuel Injector Connector HOHose Clamp Ground Cables uses eset TM4697 (O1NOVO1) 20-05-15 WTS and CWS Combines Repair PNert21. Install belt (B) and lower idler assembly (E).. 22. Connect linkage (D) using spring pin (C). E 23. Adjust rotary screen drive belt using nut and jam nut (A). ‘A—Nut and Jam Nut B-Belt (C—Spring Pin Linkage EAidler Assembly 24. Install lower fan shroud (B) using cap screws and nuts (A). | ‘A—Cap Screw and Nut (2 used) | B—Lower Fan Shroud 25. Install cooling fan (B) and spacer (C) using cap screws (A). Tighten cap screws (A) to specification, | | Specitication | cooing Fan Cap Sorows— | Torque, 60 Nem (45 to) ‘A—Cap Screw (6 used) ‘8 —Cooling Fan c—Spacer Conta on vo pags ouosssomrser -so-ssunoe-one | ‘TM4697 (01NOVO1) 20-05-16 WTS and CWS Combines Repair Pner2Remove and Install Engine | 26. Install upper fan shroud (E) using cap screws and ruts (D). 27. Install hoses (C) using clamps (A) and cap screw (B). Tighten clamps (A) to specification. | Specification Radiator Hose Clamps—Torque. 45 Nem (a0 tein) | A—Clamp i B—Cap Screw | CHoses (D—Cap Screw and Nut (10 used) E—Uppor Fan Shroud 28. Position exhaust tube (F) and attach to turbocharger using clamp (D). 29. Tighten clamp (E). | 30. Install charge air cooler tubes (C) using clamps (A) and cap screw and nut (B). Tighten clamps (A) to | specification. Recheck torque after a few hours of operation. | Specification Charge Air Cooler Tube Clamp Nuts—Torgue 11.Nem | (io) ‘A—Ciamp (4 used) B—Gap Screw and Nut | (C—charge Air Cooler Tube (2 used) D—clamp Clamp | Exhaust Tube M4697 (OINOVOT) 20-05-17. WTS and OWS Combines Repair PNeTSRemove and Install Engine | 31. Install intake duct (B) using cap screws (A). ¥ ‘A—Cap Screw (4 used) BHIntake Duct z : 32, Attach air filter assembly (F) to channel using cap sorew and nut (E). 83. Tighten clamps (A), (B) and (D). 34. Connect air filter restriction switch connector (C). 35. Install all brackets and shields, =i is A—Clamp 2 Clamp ie C—Alr Filter Restriction Switch Connector E Clamp E—Cap Screw and Nut FoAir Filter Assembly Comin on net page unsaasoomiser ~e-asuno2nsar4 TM4697 (01NOVO1) 20-05-18 WTS and CWS Combines Repair PNeT4senor and stat Ego | 36, Connect battery cables (A) and (B) to batteries. 37. Fill engine with correct oil. (See FUELS AND | LUBRICANTS in Section 10, Group 25.) | se. Fill cooling system with coolant, (See FUELS AND LUBRICANTS in Section 10, Group 25.) Cooling System (With Heater):—Specification 19540 Combine—Capacty (8 q) 9560, 9580 and 9640 Combines—Capacty. Capacty 99. For 6068 engine start-up procedure, see CTM104; for | (an | 9860 and 2680 Combines— | | | 6081 engine start-up procedure, see CTMB6. | wa697 (OINOVOH) 20-05-19 WTS and OWS Combines Repair PNA7S:| Remove and Install Engine ‘TM4697 (01NOVO1) . 20-05-20 WTS and CWS Combines Repair PNa76Group 10 Lower Engine Repair | Remove and Install Engine Oil Pan Access Sheet IMPORTANT: Engine oil pan access sheet can be reached by removing walker access cover in grain tank. if additional clearance is necessary, remove power separator. (See REMOVE AND INSTALL POWER SEPARATOR in Section 120.) Removal of this sheet will allow access to the engine oil pan area without | removing the engine. 1. Remove cap screws (A) and lower access sheet (B). 2. Install access sheet (B) and tighten cap sorews (A), ‘A~Cap Screw Be Access Sheet | ‘TM4697 (01NOVO1) 20-10-1 L 50201 woes ororss —so-oaunoy WTS and CWS Combines Repair Puc?| Lower Engine Repair ‘TM4697 (01NOVO1) 20-10-2 WTS and CWS Combines Repair PNeTE:| Group 15 | | Cooling System | Specifications 2 | Item ‘Measurement Specification | Cooling System (With Heater): 9540 Combine Capacity 36L (38 at) I 9560, 9580 and 9640 Combines Capacity 40L | | (42 an) | 9660 and 9680 Combines Capacity 45L (48 a) | Radiator Hose Clamp Torque 45 Nem | (40 Ib-in) | Radiator Test Pressure 124 kPa | (1.2 bar) (18 psi) | Radiator Cap Test Pressure 69 kPa | (0.7 bar) (10 psi) John Deere Engine Repair | For complete repair information, the component technical manual (CTM) is also required. Use the component technical manual in conjunction with this manual. [ree 1 [oe [Enaine _ [ Fesan oss crMo4e7 3 | [sea aso, e610, [ cst cTMesi255 a (seta eae i | | TWH697 GINOVOI) 20-15-1 WTS and CWS Combines Repair PNe7eCooling System Remove and Install Rotary Screen Drive Continued ons page ‘TM4697 (01NOVO1) 20-15-2 WTS and CWS Combines PretoCooling System 1—Bett ‘9—Hook Bott t7—Nut 25—Washer 2-Screw 10—Snap Ring 16 Locking Collar 26-Serew ‘3—Washer 11—Washer 19-Flange 27—Shatt Key | 4 Sheave 12) 20~Screw 28—Shatt S—sheave 13-Guide 21—Ball Bearing 29-Shalt Key | seo 14—Gauge 22-Flange Nut '30—Spring Locking Pin | roNut 15—Spring 23-Support 1 Wash | arm 16—Washer 24—Sheave | L vosassconsn ‘TM4697 (01NOVO1) 20-15-3 WTS and CWS Combines Repair PNe8tCooling System Remove and Install Rotary Screen Idler Arm and Sheaves Continued on ne pape l M4697 (01NOVO1) 20-15-4Cooling System ae a ae — an a, a a irae ae ee rom one eoay ‘TM4697 (O1NOVO1) 20-15-5 WTS and CWS Combines Repair Nees:| Cooling System Remove and Install Rotary Screen 1—Flange Nut 11—Cop Serew 21—Nut (16 used) 31—Washer (3 used) ‘2—Cap Screw (2 used) 12-Bolt (2 used) 22—Washer (16 used) 32—Rake 3Brecket 13_Washer 29—Hold Down Plate (2 used) 33—Alr Duct ‘Bumper 14—Wiring Harness 24—Screw (16 used) 34—Bushing ‘5—Flange Nut (2 used) 15—Lock Washer 25Sereen 35—Washer 6—Pin (2 used) 16—Hub 26—Hub 35—Cap Serew ‘7—Cap Screw (16 used) 17—Brush 27—Fake 37—Flange Nut (2 used) 8—Lock Washer (16 used) —18--Sereen 28—Washer (7 used) 38—Screen | s-Labet 19-Roller Bearing £28—Cap Screw (7 used) 38—Decal 10—Door 20—Snap Ring ‘30—~Cap Screw (3 used) l _ouosass 0001896 —1e-1woeTot=w ‘TM4697 (01NOVO1) 20-15-6 WTS and CWS Combines Repair PNeosCooling System Remove and Install Radiator BA CAUTION: Coolant may be hot. Wat until | radiator is cool before draining coolant. | 1. Slowly loosen radiator cap. 2. Drain radiator (A) and engine block (B). Cooling System (With Heater)-—Specifcation 9540 Combine—Capaciy 36 ea 9560, 9580 and 9640 Combines—Capacity aol wap 19660 and 9680 Combines— Capacty, 4st (ae.ay 3, Remove shields and brackets surrounding radiator. 4, Remove cap screws to remove suppor. ‘A—Radiator Drain B—Engine Block Drain Engine Block Drain Twa697 (OINOVOT) 20-15-7 WTS and GWS Combines Repair PressCooling System 5. Remove cap screws (A). 6. Remove nut (B) and slightly bend hamess retainers (C) to allow removal of harness from channel (H) 7. Remove cap screws and nuts (D). cap screws (E) and ‘cap screws and nuts (F) to remove channel (H}, 8. Loosen clamp (G) and remove intake duct (I). ‘A—Cap Screw (4 used) Nut | (C—Hamess Retainer (2 used) D—Cap Screw and Nut (2 used) E~Cap Screw Cap Screw and Nut ( used) G—clame H—channet intake Duet i uses aonage -r-amanvorns 9. Remove cap screws and nuts (A) to remove bracket (B). |e Swat eat ceo TM4697 (01NOVO1) 20-15-8 WTS and CWS Combines Repair PNBCooling System | 10. Loosen clamps (A) and remove cap screw and nut | (@) to remove charge air cooler tubes (C). ‘Clamp (4 used) | B-Cap Screw and Nut (C—Charge Air Cooler Tubes quossermcuse —se-oavorst0 11. Loosen clamps (A) and remove cap screw (B) to remove hoses (C). fan shroud (E). ‘A—Clamp (4 used) 8—Cap Screw (C—Hose (2 used) ‘D—Cap Screw and Nut (10 used) [E—Upper Fan Shroud | 12, Remove cap screws and nuts (D) to remove upper | 5 l Covina 0 ot ae cuowprsgowge spain M4697 (01NOVO1) 20-15-9 WTS and CWS Combines Repair PNse7Cooling System | 18. Remove cap screws (A) to remove cooling fan (B) and spacer (C) A—Cap Screw (6 used) Cooling Fan ‘C—Spacer 14. Install JOG19 Special Mounting Brackets (A) and | strap (). 15. Using an appropriate lifting device (C), remove the slack from strap (B) applying just enough tension to ‘support the radiator when the mounting bolts are removed, ‘A—~JDG19 Special Mounting Brackets B-Strap (C—Litting Device g ‘TM4697 (01NOVOT) 20-15-10 WTS and CWS Combines Repair pvseeCooiing System 16. Remove overflow hose (A). 17. Remove cap screws and nuts (B), cap screws (C), cap screw and nut (D) and cap screw (E). A-Overfiow Hose BCap Screw and Nut (2 used) (GCap Screw (3 used) D—Cap Screw and Nut E—Cap Screw Continued on not poe ‘TM4697 (01NOVO1) 20-15-11 WTS and CWS Combines Repair PNags| Cooling System NOTE: Be careful not to damage radiator fins andor seals when lifting from combine. 48. Carefully lit radiator from combine. 19. Clean and inspect radiator for damage. Repair or replace radiator as necessary. 1 | 20. Inspect seals for damage. Replace as necessary. 21. Install in reverse order and tighten radiator hose clamps to specification. Specitcation Radiator Hose Clamp—Terque 45.Nem (40 bein) 22. Fill radiator with coolant. + 9540 Combine—36 L (98 gt) ‘+ 9560, 9580 and 9640 Combines—40 L (42 qt) ‘+ 9660 and 9680 Combines—45 L (48 qt) Test Radiator | Remove cap and visually check radiator for leaks or damage. Attach DO5104ST tester in radiator neck. Pressurize | radiator according to specifications. Repair radiator if 2 pressure will not hol. 5 Specification 5 Radiator—Prossure 126 kPa : (12 bar) 2 (18 psi) E | | ‘TM4697 (01NOVO1) 20-15-12 WTS and CWS Combines Repair PN=90Cooling System | Test Radiator Cap Install D05104ST tester. | Pressurize cap according to specifications. The cap should hold this pressure and relief should occur close to 69 kPa (0.7 bar) (10 psi) L | Specification | aciator Cap—Presure 124400 | (12 ban (eps) Replace Thermostat To replace thermostat on Combine, see CTM104 for 6068 engine and CTM86 for 6081 engine. Repair or Replace Water Pump To repair or replace water pump on Combine, see CTN104 for 6068 engine and CTM86 for 6081 engine. TM4697 (01NOVO1) 20-15-13 WTS and CWS Combines Repair PNeet| Cooling System ‘TM4697 (01NOVO1) 20-15-14 ~ WTS and CWS Combines Repair PNeeeSection 30 Fuel and Air System. | Contents | Page | | Group 05—Air Intake System | Other Material 30-05-1 Specifications . 1 130-05-1 John Deere Engine Repair . 30-05-2 Remove and Install Turbocharger 30-05-3 Remove and Install Charge Air Cooler 20-05-5 | Remove and install Air Cleaner Filters 30-05-15 | | | Group 10—Diesel Fuel System | | Other Material 30-10-1 | | Spectications 1130-10-41 | Remove Fuel Tank - 30-10-2 | | Remove and Install Fuel Level Sensor 3010-7 | Remove and Install Fuel Tank Strainer... ..20-10-7 Remove Fuel Tank Outlet Screen 30-108, install Fuel Tank Outlet Screen 30-108, Bleeding Combine Fuel System ......... 00-10-10 Replace Cold Weather Starting Aid Can... 30-10-11 | Remove and Install Cold Weather Starting | Aid. : 30-10-11 | | | | | | | | TM4697 (01NOVO1) 30-1 WTS and CWS Combines Repair PNetContents | ~ | ‘TM4697 (01NOVO1) 30-2 WTS and CWS Combines Repair PNez| | eS | Other Material Number Name | PTs69 (U.S.) NEVER-SEEZ | | Ty24345 (U.S.) ATV Silicone Adhesive Sealant |LINEVER-SEEZ isa trademark of Emhart Chemical Group Use Protects parts against seizure, corrosion, pitting, and galling, To seal out dust and debris from the cooling package. Group 05 | Air Intake System | Specifications sem Measurement Specification Turbochargerto-Exhaust Manifold Torque 24 Nem Cap Screws (18 lb-t) Turbocharger Oil Lines Torque 34 Nem : (25 lb-ft) | | Charge Air Cooler Tube Clamp: Torque 11.Nem | (97.4 fosin) Charge Air Cooler Weight 27 kg (60 lb-ft) Radiator Hose Clamp Torque 4.5 Nem | | (40 tin.) | | | | 7Ma697 (O1NOVOI) 30-05-17 WTS and CWS Combines Repair PN=8S| Air Intake System | John Deere Engine Repair For complete repair information, the component technical ‘manual (CTM) is also required, Use the component technical manual in conjunction with this manual j Combine Engine i 540 nee 5] 8560 580.9600, | coat al 9650 and 680, z|| | | cross -wsannicns | ‘T4697 (O1NOVOT) 30-05-2 WTS and CWS Gombines Repair PN=6Al Intake System ‘TM4697 (O1NOVO1) Remove and Install Turbocharger 1. Loosen clamps (A) to disconnect charge air tube (B). 2. Loosen clamp (C) to disconnect air intake hose (D). 3. Disconnect ol lines (E) and (F). 4, Remove clamp (G) to disconnect exhaust tube (I. 5. Remove four cap screws (H) and turbocharger. (See CTMB6 for turbocharger repair.) Plug and cap all ‘openings to prevent contamination from entering system. IMPORTANT: If turbocharger failed because of foreign matter entering the air intake system, be sure to examine the system and clean as required to prevent a repeat failure. Visually inspect the charge air cooler and clean if necessary. Oil may have accumulated from the failed turbo. 6. Prime (prelube) turbocharger rotating assembly prior to installing turbocharger on engine. Prelube center housing with clean engine cil through oil line (top opening) hole (E). Tum rotating assembly by hand to lubricate bearings. NOTE: Two threaded guide studs may be used to hold turbocharger-to-exhaust manifold mounting surface, 7. Put new gasket on turbocharger-to-exhaust manifold mounting surface. 8, Position turbocharger against gasket in exhaust manifold, 9, Apply PTS69 NEVER-SEEZ* Compound to all turbocharger mounting cap screws. Install cap screws and tighten to specification, NEVER.SEEZ isa trademark of Emhart Chemical Group Comtinnd on nest page 30-05-3 2 H_Cap Screw (4 used) exhaust Tube WTS and CWS Combines Repair PNegT| Air Intake System Specitication ‘Turbochargarto-Exnaust Manta Cap Serens—Torque. 24 Nem (8 tot) 10. Connect muftler and tighten clamp (GB). 14. Connect ol lines (E) and (F) tighten to specification, Specification Turbocharger Ol Lines—Torque. 34 Nem (25 tet) 42. Connect air intake hose (D) and tighten clamps (C), 18. Connect charge air cooler tube (B) and tighten clamps (A) to specification Specification Charge Ar Colr Tube Camp | | Sore 11m | (97-4 Ib-in.) M4697 (01NOVOT) 7 30-05-4 WTS and CWS Combines Repair PN=g8:Air Intake System Remove and Install Charge Air Cooler 1. Remove covers, shields and supports surrounding charge air cooler. 2. Open rotary screen door. Remove cap screws (A). 3. Remove nut (B). 4, Remove witing hamess from hamess retainer (C). 5. Remove cap screws and nuts (D), cap screws (E) and (F) to remove channel (H). 6. Remove clamp (G) to remove air fiter intake duct (I) A~Cap Screw (6 used) BoNut (C—Hamness Cap Retainer (2 used) D—Cap Screw and Nut (2 used) Cap Serew (2 used) Cap Screw and Nut (2 used) G—Ciamp H—Channet intake Duet ‘TM4697 (01NOVO1) 30-05-5 WTS and CWS Combines RepairAir Intake System | IMPORTANT: Clean area surrounding charge air cooler tubes to help prevent contamination of system during service. 7. Loosen clamps (A), cap screw and nut (B); then remove charge air cooler tubes (C). ‘A—Clamp (4 used) B—Cap Screw and Nut (Charge Air Cooler Tube (2 used) 8. Remove cap screws and nuts (A) and bracket (B). | ‘A~Cap Serew and Nut (2 used) Bracket ‘TM4697 (01NOVO1) . 30-05-6 WTS and CWS Combines Repair PN=100Air Intake System CAUTION: Coolant may be hot. Wait until radiator is cool before draining coolant. 9. Loosen clamps (A), remove cap screw (B) and radiator } hoses (C). ) 10. Remove cap screws and nuts (D); then remove upper ») j 5 (es ) j yy, | fan shroud (E) ‘A—Clamp (4 used) | BCop Screw | (C—Radlator Hose (2 used) [D—Cap Screw and Nut (10 used) Upper Fan Shroud 2 g é 3 i | 11. Remove cap screws (A), cooling fan (B) and spacer | ‘A—Cap Screw (6 used) Coating Fan c—Spacer g | i Twaeo7 (INOVOT) 30-05-7 WTS and CWS Combines Repair PNet01Al Intake System | 42. Remove cap screws, nuts (A) and lower fan shroud | (B). ‘A~Cap Screw and Nut (2 used) ‘B—Lower Fan Shroud 13. Connect strap and suitable lifting device to charge air Ne | cooler and apply ust enough tension to support | charge air cooler before removing mounting bolts. M4697 (01NOVO1) ~30-05-8 ~~ WTS and CWS Combines Repair PN=t02Air Intake System | 14, Remove cap screws and nuts (A) and (B). ‘A—Cap Screw and Nut (2 used) BCop Serow and Nut (2 used) 18. Remove cap screw and nut (A) and (B). | ‘A—Cap Screw and Nut BX Cap Screw and Nut 2 used) A 8 8 T4697 (01NOVOT) 30-05-9 WTS and CWS Combines RepairAir Intake System NOTE: Be careful not to damage cooler fins and/or seals when lifting cooler from combine. 16. Lift charge air cooler from combine. = \ Specitication ‘Charge Air Coolr—Weight arkg | (601) 17. Clean and inspect cooler for cracks andior damage. Replace as necessary 18. Inspect seals for tears andior damage. Replace as necessary. | NOTE: Be careful not to damage cooler fins and/or seals | when installing cooler in combine. 19. Install charge air cooler. Spectcation Charge Air Coler—Weigt ag (60) 20. Install cap screws and nuts (A) and (B) | -AeCap Serew and Nut Cap Serew and Nut (2 used) H E | Continaad on next page _ouosos7.c0a1467 ~18-s0,uLor—ri1e | M4697 (O1NOVO1) 30-05-10 WTS and CWS Combines Repair PNei08| Air Intake System 21, Install cap screws and nuts (A) and (B). ‘A~Cap Screw and Nut 2 used) 1B Cap Screw and Nut (2 used) | | | Cuneornoioray -raagunotatate | 22. Attach lower fan shroud (B) using cap screws and nuts (A), ‘A—Cap Serew and Nut (2 used) Lower Fan Shroud ‘TM4697 (01NOVO1) ~~ 30-05-11 WTS and CWS Combines Repair PNet05Air Intake System 23. Install spacer (C) and cooling fan (B) using cap screws (A), ‘A~Cap Screws (6 used) B-Cooling Fan c-Specer | 24. Install upper fan shroud (E) using cap screws and nuts (0), 25. Install radiator hoses (C) using clamps (A) and cap screw (B). Tighten clamps (A) to specification, Specitication Radiat: Hose Clamp—Torgue 45.Nm (40'bin) © A—Clamps (4 used) Cap Screw (C—Radiator Hose (2 used) D—Cap Screws and Nut (10 used) Upper Fan Shroud 26. Attach bracket (B) using cap screws and nuts (A). ‘A~Cap Serew and Nut (2 used) Bracket ‘TM4697 (01NOVO1) 30-05-12 WTS and CWS Combines Repair PN=106| | Airioke System | | IMPORTANT: Be certain that tubes are free from dirt ean and debris before installing to charge | air cooler. | 27. install charge air cooler tubes (C) using clamps (A), cap screw and nut (B). Tighten clamps (A) to specification. ‘Specification charge Ai Cooler Tube (Clamps—Torque, 11Nem (074 tein) Frere suneteuAvr ‘A—Clamp (4 used) B—Cap Screw and Nut (—Charge cooler Tube (2 used) | | 3 | g a | comings cn net pat uosssranous) cieanustse 7w4697 (01NOVO1) : 30-05-13 WTS and CWS Combines Repair PNeto7| Air Intake System 28. Install ar intake duct (I) using clamp (G) and cap a screws (A. 29. Attach wiring harness to bottom of channel (H) using harness retainer (C) 30. Install channel (H) using cap screws and nuts (D), cap screws (E), cap screws and nuts (F) and nut (B). 31. Install remaining covers and shields. (C—Harness Retainer (2 used) D—Cap Screws and Nut (2 used) E—Cap Screws (2 used) F—Cap Sorews and Nut (3 used) G—Clamp channel Air Fiter Intake Duct ‘TM4697 (01NOVO1) 30-05-14 WTS and CWS Combines Repair PN=108Alir Intake System | Remove and Install Air Cleaner Filters 1. Open four clips and remove dust cover (A). 2. Pull out primary fiter (B) | 3. Pull out secondary fiter (C) 4, Install filters (C) and (B) and attach cover (A). | a—dust cover Primary Filter C—Secondaty Fier .9560 and 9660 Air Cleaner Shown ‘TM4697 (01NOVO1) 30-05-15 WTS and CWS Combines Repair PNet0sAir Intake System ‘TM4697 (01NOVO1) 30-05-16 WTS and CWS Combines Repair PNeH10Group 10 | Diesel Fuel System Other Material Number Ty9974 (U.S.) TEFLON is @ tadomark of Du Pont Co. Name Pipe Sealant with TEFLON’ Use. To seal threads of shut-off valve. | Specifications | tem Measurement ‘Specification | Fuel Tank Capacity 700 L | (185 ga | Fuel Tank Weight 57 kg (126 Ib) Diagnostic Port Torque 14 Nem (10 lb-ft) | High Pressure Fuel Lines Torque 27 Nem | | (20 lb-ft) | Tw4697 (01NOVOT) 30-10-1 WTS and CWS Combines Repair PNetnt| Diesel Fuel System Remove Fuel Tank ea TM4697 (01NOVO1) 30-10-2 WTS and CWS Combines Repair PNett2Diesel Fuel System 1—Fuel Tank Strainer 15Drain Va 22-Cap Sorew 2-Breather 9—Chain 16-Fiting 23—-Gasket | 3-Clip (2 used) 10-Ring 17—Fuel Fiter 24—Gasket 4 Hos 11—Grommot 18—Vaive 25—-O-Ring (2 used) S—Adapter 12-Vent 19-Fuel Sender 26—Anchor 6-Filler Cap 12—Clamp (2 used) 20—Hose 27—Cap Serew TO-Ring 14Fitting 21—Clamp 28—Hose | NOTE: Fuel tank configuration will vary depending on ‘model. Removal procedures may be slightly different, 4. Drain fuel from tank by opening petcock (A). Specitication Fuel Tank—Capacty 700 (8s gay CAUTION: The approximate weight of engine access door is 46 kg (102 Ib). NOTE: Use a suitable Itting device to support engine A-Petcock access door. 2, Remove engine access door. 3, Remove tube (A), panel (C} and door (B) | 4, Disconnect hose from fue! tank breather located under | radiator housing, | tube | B—Door | eoPanet | | s | 2 | 5 | 3 | : \ coined out poe cuotersones asain | TMa697 (O1NOVO?) 30-10-3 WTS and CWS Combines Repair PNett3| Diese! Fuel System | 5. Remove wiring hamess (A) from rear ladder and landing assembly (0). 6. Remove cap screws (B) and light assembly (C), Ay CAUTION: The approximate weight of the rear ladder and landing assembly is 102 kg (225 Ib). Use appropriate Ii ing device. 7. Remove hinge bolts (E) and landing assembly (D). C—Light Assembly D—Rar Ladder and Landing Assembly E-Hinge Bolt 2 used) 8. Remove cap screws (A) and brace (B). A—Cap Screws (2 used) Brace ‘TM4697 (01NOVO1) 30-10-4 WTS and CWS Combines Repair PNetial Diesel Fuel System oe | ‘A-Connector | 10. Disconnect fuel return line (A). 41, Remove fuel line at fiting (B) ‘A—Fuel Return Line B—Fitting | 12. Flemove cap screws (A) and brace (B). ‘A~Cap Serow (2 used) |B Brace M4697 (01NOVO1) 30-10-5 WTS and CWS Combines Repair PNetiS,Diesel Fuel System 13. Loosen flange nut (A), 14, Remove cap screw (8). ‘A—Flange Nut B-Cap Screw Loupsosroonnes9 sonora 1. Remove cap screw (A). 16. Remove cap screws (C), flange nuts (B) and fuel tank support (0). AY CAUTION: The approximate weight of fuel tank is 57 kg (126 Ib). ‘Specitication Fuel Tank Weight s7kg 17. Slide fuel tank out right-hand side of combine. 18. Install in reverse order. ‘A~Cap Screw B—Flange Nut (3 usea) (C—Cap Screw (3 used) D—Fuel Tank Support i ‘TM4697 (01NOVO1) 30-10-6 WTS and CWS Combines Repair PNeti6Diesel Fuel System Remove and Install Fuel Level Sensor 4. Clean area around fuel sensor to avoid contaminating | fuel supply when sensor is removed. 2. Disconnect connector (A) to fuel level sensor. NOTE: Observe how float arm is positioned in relation to fuel tank. This will simplify reassembly. 3, Remove six screws (B), fuel level sensor (C) and gasket (D). Sensor can not be repaired. f damaged, it must be replaced, | 4. Install fuel sensor using new gasket (D). Guide fuel level sensor (C) through top of fuel tank with float arm positioned toward center of tank. Install five screws (B). | 5. Connect connector (A) to fuel level sensor. | | Remove and Install Fuel Tank Strainer 1. Lift and turn lever (A) to remove cap (B). Remove strainer (C) and clean or replace as necessary. 3, Install parts (A—C). B-Cap | foo. | C—Strainer TMa697 (01NOVO1) 30-10-7, A—Connector B-Screw (5 used) (C—Fuel Level Sensor D—Gasket WTS and CWS Combines Repair PNen7le Diesel Fuel System Remove Fuel Tank Outlet Screen 1. Drain fuel from tank by opening petcock (A). 2, Remove shut-off valve (B) from bottom of tank. ‘A—Petcock B—Shut-of Valve 3. Remove screen (A) from shut-off valve (B). NOTE: If screen is clogged with dirt and debris, | thoroughly flush fuel tank, 4. Clean screen with solvent or replace if necessary 4 | Install Fuel Tank Outlet Screen | 1. Install soreen (A) on shut-off valve (B). An Sereen B—ShutOf Valve g i a Continued on nxt Lcuveaszcoouuss -1ponanorie | ‘TM4697 (01NOVO1) 30-10-8 WTS and CWS Combines Repair PNeti8Diesel Fuel System | 2. Apply TY9374 Pipe Sealant with TEFLON® to threads |? APRs ve 6) and instal ave in tank | 9. Fill tank with fue. 4, Bleed fuel system. (See procedure in this section.) Acpeteock eTghur ot Vaive ' | | | | semow ns want fet ee 5juaeo7 (O1NOVOT) 30-10-9 WTS and OWS Combines Repair PNet 19Diese! Fuel System | I Bleeding Combine Fuel System 1. Drain water and contaminates from water separator | bow! (A) by opening drain (B), | 2. Connect JT03472 coupler and hose to diagnostic port | (©). If.1708472 coupler is not available, loosen the | diagnostic port to allow air and fuel to escape. Bleed fuel into suitable container, NOTE: Hand primer must be pulled all the way up between pumps. 3. Unlock and operate hand primer (D) until a steady flow of fuel (without bubbles) flows out of hose. NOTE: It can take up to 200 strokes until fuel comes out steadily. 4. Continue to pump hand primer while disconnecting | 4103472 coupier tom dlagnastic por. or while tightening diagnostic port to specication -~ | cues fot-Tac. erin soem Mls Sed (10 bot) 5. Start engine and run engine at high idle CAUTION: If engine has not been cranked after Pumping of the hand primer, fuel lines will be under pressure. Wear face protection and loosen fittings slowly in order to relieve | pressure and avoid excessive spraying of fuel. 6. If-engine fails to start, loosen high pressure fuel lines | (E). Pump hand primer until steady flow of fuel escapes the fuel pump. Tighten fuel lines to specification and lock hand primer (pull up, then push | down and lock), ‘A—Water Separator Bow! BODrain Valve ‘©—Diagnostic Port Hand Primer E-High Pressure Fue! Lines ‘Specitication | High Pressure Fue! Lines— Torque 27 Nem | (20) 7. Start engine. If engine fails to start. repeat step 6. M4697 (01NOVO1) 30-10-10 ~ WTS and CWS Combines Repair PNet20Diesel Fuel System r Replace Cold Weather Starting Aid Can D. SAUTION: Starting fuid is highly flammable. Do ) not use fire, sparks or flames. Read the cautionary information on the container. Protect | container against damage. | IMPORTANT: To avoid drawing dust into engine, always keep a starting fluid can in position. | 1. Remove safety cap and plastic spray nozzle from new | container. ae 2. Loosen canister (A) to remove old can. 3, Install new can and tighten canister. Remove and Install Cold Weather Starting Aid 1, Remove parts (A—F). | 2. Inspect parts for wear or damage. Replace it | necessary. 3. Install parts (A—F). A~Cap Screw (2 used) B-Connector (C—injector Line oon E—Canister F-Body t nino et ge ‘TM4697 (01NOVO1) 30-10-11 WTS and CWS Combines Repair PN=121Ll Diesel Fuel System | | 4H staring ait does not operate aroper, isconect line (A) and remove spray nozzle (B) from manifold, | | 5. Clean nozzle and install nozzle and line. IMPORTANT: Be sure nozzle is secure in adapter. If nozzle is loose, engine may be damaged. However, over tightening will | break nozzle. Actine B Nozzle Tw4697 (01NOVO1) 30-10-12 WTS and OWS Combes Repar PNei22Section 40 Electrical System \ Contents | Page Page | Group 05—Batteries Relays, 40-20-5 | Prevent Battery Explosions --40-05-1_Power Distribution Board Relay Handling Batteries Safely 4005-2 Identification 40-206 | | Prevent Damage to Electrical Systems 40-05-3 Engine Compartment Relay Panel Fuse i | Checking Electrolyte Specific Gravity 40-05-4 Identification 4020-7 | Battery Replacement. . 40-055 Engine Compartment Relay Panel Relay | Remove, Clean and Install Batteries 40-05-6 ‘dentification . os 40-208 | Connecting Booster Batteries 40-05-6 i | Charging Batteries. . 40-05-7, se | Connecting Battery Cables 1140-05-8 Group 25—Lighting Safety ules When Replacing Halogen Group 10—Harness and Connector Repair Fale 40-25-41 cee ear Recaramended Took en goctost Cab Head Light Bulb Replacement and Other Material “40-10-2 Adjustment. 40-25-1 Use Electrical Insulating Compound ..40-10-2 Auxiliary Field and Access Door, Wark Light Using High-Pressure Washers 40-10-2 Bulb Replacement... 4025-2 | Repair WEATHER PACK Connector. '40-10-3 Rear Discharge Light Bulb Replacement... . .40-25-2 Remove Connector Body from Blade Side Finder Light Bulb Replacement 40-25-38 ‘Terminals. 40-10-5 Grain Tank and Unloading Auger Light Bulb | | Repair (Pull Type) METRI-PACK™ Replacement 40-25-3 | Connectors: 40-106 Cleaning Shoe Light Bulb Replacement ... ..40-25-4 | Repair (Push Type) METRI-PACK Turn Signal and Maximum Tilt indicator Light | | Connectors. 40-10-7 Bulb Replacement 40-25-4 | Repair CPC™, Large MATE-N-LOC™ and Dome and Console Light Bulb Replacement, . .40-25-4 | _METRIMATE™ Pin Type Connectors. .... 40-10-10 GommandTouch” CornerPost Monitor Light | Repair GPC Bla Tyne Connects... 40-10-11 Bulb Replacement 40-25-5 a —LUr—e gorora Waiting Display Panel Light Bub | | Replacement 40-25-6 Repair Small MATE-N-LOC Pin Connector. . 40-10-13 yeader Float Gauge (Optional Bulb | | Repair DEUTSCH Connectors ....... 40-10-14 Replacement, eS Repair CINCH Connectors 40-10-16 Group 15—Wiring Harness Routing Group 30—Operator's Station Replace Harness. « 40-15-1 Other Material 40-30-1 Cab Main Wiring Harness 40-15-2 Specifications 40-30-1 Left-Hand Main Wiring Harness. 40-15-3 Instruments and Controls Identification 40-30-2 Right-Hand Main Wiring Hamess, With ‘Overhead Waming Display Panel 40-30-3 GREENSTAR™ 40-15-4 Remove and Install Overhead Console. 40-30-4 Engine Wiring Harness - Reference 140-15-5 Replace Overhead Waming Display Panel Circuit Board 40-30-5, Group 20—Fuses, Circuit Breakers and Relays Remove and Install Light Panel Dimmer Specifications . : 40-20-1 ‘Switch 40-30-5 | | Basic Operation 40-20-2 Remove and Install Overhead Display Rocker Power Distribution Board | System Basic ‘Switches 40-30-6 | Description 40-208 | Circuit Board Replacement 40-20-3 Continued on next page | TMa697 (O1NOVOI) 40-1 WTS and GWS Combines Repair PN\ Contents | Page Page | Remove and Install ClimaTrak”™ Automatic Remove and Install (Shoe/Separator) Air Conditioning/Heater Temperature VisionTrak™ Sensors. 40-35-5 Control Switch and Fan Switch --40-30-7 Remove and install (Return to Gut and Remove and Install Radio. 40-30-7 Tilt) Header Heigh/Ground Pressure Control Remove and Install Radio Speaker 40-30-8 Sensors. 40-95-6 Remove and Install Radio Antenna 40-20-9 Remove and Install Coolant Temperature CornerPost Main Circuit Board Removal... .40-30-10 Sensor. 40-35-7 Remove Header Control Module 40-30-11 Remove and Install Fuel Level Sensor... 40-38-9 Remove Performance Monitor and Digital Remove and Install Park Brake Switch ..... 40-36-10 Tachometer Module. 40-30-12 Remove and Install Air Filter Restriction | Digital Tachometer Calibration =-40-30-13 Switch + 40-96-10 | COMMANDTOUCH Console Controls, “40-30-14 Remove and install Engine Gear Case Rertiove and Install CommandTouch® Temperature and Pressure Switches... ... 40-35-11 Console... 40-30-16 Remove and Install Hydro Charge Remove and Install Header and Separator Pressure Switch 40-35-11 | Engage Switches ..40-30-17 Remove and Install Hydraulic Reservoir Remove and Install DIAL-A-SPEED™ and ‘Temperature Sensor «40-95-12 Header Height/Ground Pressure Control Remove and Install Engine Oil Pressure Switches 40-30-18 ‘Switch 40-95-12 Remove and Install CimaTrak™ Solar Remove and install Service and Cleaning Sensor. 40-30-19 Shoe Light Switch 40-35-13 Remove and Install Back Light Bulbs for DIAL-A-SPEED and Header Group 40—Wiper Height’Ground Pressure Control Specifications 40-40-1 Switches 40-30-19 Remove and Install Wiper Motor -40-40-1 Remove and Install CommandTouch™ Adjust Long Windshield Wiper. 40-40-4 ‘Console Membrane Switches 40-90-20 Remove and Install Windshield Washer 40-40-6 Remove and Install CommandTouch™ Console Circuit Board ...... 40-30-24 Group 45—Alternator | Replace Neutral Safety Switch + 40-30-25 Specifications oe | Replace Mini Hamess 40.3026 John Deere Engine Accessories— Remove and Install Multi-Function Handle . . 40-30-27 Alternator Repair-—Use CTM77 fot Remove and Install Start Switch... GO S28 | eee cae Geer eee ‘eae | Remove and Install Starting Aid Switch. . .. . .40-30-29 Lala ead ae Teac Remove and install Turn Signal/Side Finder | Light Switch 40-30-29 . femove and instal Horn Sith 40-309 $oup 50—Starting Motor Remove and Install Mirrors 40-30-30 Specifications oa Remove and Install Mirror Switch oot si eee eed Repair—Use CTM77...... 40-50-4 | Remove and Install Starting Motor « 40-50-1 Group 35—Sensors and Switches Remove and Install Starter Relay 40-50-2 Other Material 40-35-1 Shatt Speed Sensor Locations 40-35-1 Group 55—GREENSTAR Components Remove and Install Conveyor Auger, Tailings Specifications . 40-55-1 | Elevator, Grain Elevator and Grain Separator Remove and Install GREENSTAR Mass-Fiow Sensors. 40-35-3 Sensor. 40-55-1 Remove and install Cleaning Fan, Cylinder Remove and Install GREENSTAR Paddle | Speed and Feeder House Backshait Speed Wheel 40-55-4 | _ Sensors. 40-35:3 Remove and install GREENSTAR, | Remove and install Staw Chopper Sensor. ...40-35-4 Moisture Sensor. = 40-55-4 Remove and Install Grain Tank Sensor. 40-35-4 Remove and Install Tailings Sensor 40-35-5 Continued on next page ‘TM4697 (01NOVO1) 40-2 WTS and CWS Combines Repair PN?\ Contents | 1 j Page ) | | Remove and Install Position Receiver. ...... 40-85-7 | | | | | | | | | | | | | | | - S J ‘TM4697 (01NOVO1) 40-3 WTS and CWS Combines Repair PN=3Contents L ‘TM4697 (01NOVO1) 40-4 WTS and (CWS Combines Repair PwPrevent Battery Explosions Keep sparks, lighted matches, and open flame away from | the top of battery. Battery gas can explode. Never check battery charge by placing a metal object, across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). TMa697 (OINOVOI) 40-05-1 Group 05 Batteries WTS and CWS Combines Repair pasts| Handling Batteries Safely sparks and flames away from batteries. Use a | A CAUTION: Battery gas can explode. Keep | | flashlight to check battery electrolyte level. i object across the posts. Use a voltmeter or | Never check battery charge by placing a metal hydrometer. Always remove grounded (-) battery clamp first and replace it last. | AY CAUTION: Sutturic acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. ‘Avoid the hazard by: 1. Filling batteries in a well-ventilated area, 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte, 5. Use proper jump start procedure. | If you spill acid on yourself: | 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. acid is swallowed: 1. Do not induce vomiting, | 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately. } ‘TM4697 (01NOVO1) 40-05-2l Batteries | Prevent Damage to Electrical Systems | To prevent damage to electrical system components, | alvays obseve these precautions | 1. wen working on electrical systems powered rom he ttcieeaconnect negative () gound by tung | Randle (A) countorcocewso and removing completly from post pore performing repair. | 2. Never disconnect the batteries with the key switch on | Orne engi ing | 3. Never connect jumper cables with the key switch on. & Disconneat batteries when charging tem The combine should be jump started By 12 vols ONLY. Aways charge the bateris witha charger set for 12 volts. 7. Newer connest or disconnect wring hamess connectors wan the key awen on @. Do not apply power or ground to any component a8 toot unos rateted A-Handle ‘TM4697 (01NOVO1) 40-05-3 WTS and CWS Combines Repair PNet27| Batteries | ir . | Checking Electrolyte Specific Gravity | i A CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. | Always remove grounded (-) battery clamp first | and replace it last. Sulfuric acid in battery electrolyte is poisonous. | Itis strong enough to burn skin, eat holes in | clothing, and cause blindness if splashed into eyes. | Avoid the hazard by: 1. Filling batteries in a well-ventilated area. | 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. | If you spill acid on yourself: | 1. Flush your skin with water 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. | tracid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do | not exceed 1.9 L (2 quarts). 3. Get medical attention immediately, | Check the specific gravity of electrolyte in each battery as | cell using a battery and coolant tester such as JT05460 “ | Battery/Coolant Tester | Follow directions included with the tester. T4697 (01NOVOT) 40-05-4 WTS and CWS Combines Repair PN=i28Batteries A ully charged battery will have a corrected specific | gravity reading of 1.260. It the reading is below 1.200, | charge the battery. NOTE: In tropical areas, use 1.225 for the ful charge | reading. In cold areas, use 1.280 for the | fultcharge reading | | Battery Replacement Two 12-volt batteries connected in parallel provide a 12-volt electrical system. When replacing batteries, use John Deere batteries or ‘equivalent. Both batteries must have the same rating. 1 Reserve Capacity | | Cold Cranking | Minutes at 25 Volts _ John Deere Part No. C1 Group ‘Amps 0°F (18°C) | Amps | | pe yet? 3 625 [0 2 Ty8128 3 950 180 | [e Tete? 2 625 1682 | ac.ovosne ye -sessauiono ‘TM4697 (01NOVO1) 40-05-5, WTS and CWS Combines Repair PNe129= | Remove, Clean and Install Batteries | | 1. Disconnect negative (-) cable (B) and then disconnect. Positive (+) cable (A). 2, Remove battery clamp (C) to remove batteries. 8, Clean batteries and battery mounting area. 4, Install batteries using clamp (C) | 5. Connect positive (+) cable (A) and then negative (-) cable (8). ‘A—Positive Cable B_Negative Cable c—clamp. Connecting Booster Batteries | Cold weather starting can be easier by connecting an ‘additional 12-volt battery in parallel CAUTION: Gas given off by batteries is explosive. Avoid sparks near batteries. IMPORTANT: Never connect jumper cables with key switch on. Never jump-start with more than 12 volts. First jumper cable (A) must connect positive (+) post of booster battery to positive (+) post of combine battery Second jumper cable must frst be connected to negative | © post of booster battery and then to a good ground on| combine, away from combine batters. ‘TM4697 (01NOVO1) 40-05-6 l Batteries ‘A—Positive Post ac.ovceosn 280 -¥ WTS and CWS Combines Repair PN=190| Batteries | Charging Batteries | keep battery fully charged, especially during cold weather A CAUTION: Never charge a frozen battery. Thaw battery charger. Only charge batteries in a well ventilated area. Disconnect both cables from | battery terminals when charging batteries in | combine. Disconnect both battery cables and connect charger positive cable to “+” terminal and charger negative cable Follow instructions provided with charger. Always charge batteries with a 12-volt charger. M4697 (O1NOVO1) 40-05-7 WTS and CWS Combines Repair PNatSt| Connecting Battery Cables | QQ CavTION: BATTERIES ARE NEGATIVE GROUNDED ONLY. Always connect battery ground strap to negative (-) posts of battery. Connect starter cable to positive (+) post of battery. Reversed polarity in battery or alternator connections results in permanent damage to electrical system. Connect ground strap to negative (-) terminal last. IMPORTANT: Batteries must have same terminal locations. When connecting batteries: ‘Tum off all switches and accessories. Clean battery posts and terminals QUICKLY TAP ground strap to negative post. Arcing must Not occur. If arcing occurs, DO NOT MAKE CONNECTION. Check to see if battery position is reversed, It arcing stil occurs, check again that all switches and accessories are off. Then check for shorts or other electrical loads. Connect negative (-) battery ground cable. ‘TM4697 (01NOVO1) 40-05-8 WTS and CWS Combines Repair Pret32Essential or Recommended Tools European Microfiche Too! Catalogs. job correctly and are obtainable only from ‘SERVICEGARD or European Microfiche Too! Catalogs, NOTE: Order tools from the U.S. SERVICEGARD or ESSENTIAL TOOLS listed are required to perform the | Group 10 Harness and Connector Repair RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers or may be fabricated. Technician's Electrical Repair Kit Repair wire connectors, WEATHER PACK" Crimping Too! Crimp contacts to wires WEATHER PAGK is a vademark of Packard Elect Electrical Repair Tool Kit. Repair electrical connectors - JDGI5S aE SS JT071958 - JDG783 Crimping Tool. Crimp contacts to wires JDG8E5 TM4697 (O1NOVO!) 40-10-1 WTS and CWS Combines Repair PNeta3Hamess and Connector Repair DEUTSCH” Electrical Repair Tool Kit JOG359 Repair DEUTSCH electrical connector bodies DEUTSCH isa trademark of Dewrscn Co, | Other Material Number Name | AT6686S (U.S.) (U.S.) Lubricant Use Electrical Insulating Compound Apply AT66865 Compound directly to the terminals between the wire seal and connector body. This provides ‘a moisture barrier. especially in wet and humid conditions, IMPORTANT: Directing pressurized water at electronic/electrical components or | connectors, bearings and hydraulic | seals, fuel injection pumps or other Using High-Pressure Washers e@ Use Insulate electrical connectors so-smuavoru | sensitive parts and components may z| cause product malfunctions. Reduce 3 pressure, and spray at a 45 to 90 3] degree angle. 2 i u cvoetminnss re gussets TM4697 (01NOVO1) 40-10-2 WTS and CWS Combines Repair PN=134| Harness and Connector Repair IMPORTANT: Identify wire color locations with | Repair WEATHER PACK Connector \ | | | connector terminal letters. | Open connector body. i Insert JDG364 Extraction Too!’ over terminal contact in connector body. | NOTE: If terminal cannot be removed, insert wire or nail through extractor too! handle and push terminal | | contact from connector. || Hold extractor tool fully seated and pull wire from connector body. ‘eluded in JTO71958 Electrical Repair Kit Continued on nest page Louosmasse29 ~o-1eavor ‘TM4697 (01NOVO1) 40-10-3 WTS and CWS Combines Repair PNeta5| Hamess and Connector Repair = NOTE: Cable seals are color coded for three sizes of ‘. wire: Z | + Green - 18-20 Gauge Wire * Gray - 1416 Gauge Wire + Blue - 10-12 Gauge Wire | IMPORTANT: The seal must fit snug over the cable | insulation, without a gap between the cable seal and the insulation. i ? 5 3 a Push correct size cable seal on wire. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation. NOTE: Contacts have numbered identification for two sizes of wire: #15 - 1416 Gauge Wire + #19 - 18-20 Gauge Wire Put correct size contact on wire and crimp in position with . a a W-lype crimp using a JDG783 Weather Pack Crimping 2 | Tool | won ngage voc somo —rssauner-8 ‘TM4697 (01NOVO1) 40-10-4 WTS and CWS Combines Repair P96| Harness and Connector Repair ' - 1 | IMPORTANT: Contact lances must be carefully spread to ensure good seating on connector body. NOTE: Connector bodies are "keyed" for correct contact. Be sure contacts are correctly aligned. Correct contact installation for sleeve (A) and pin (8) is ilustrated | | Push contact into new connector body until fully seated. Pull on wire sightly 10 ensure contacts locked in position. Transfer remaining wires to correct terminal in new connector, Close connector body. A-Sleove B-Pin | Remove Connector Body from Blade | Terminals Depress locking tang (A) on terminal using a small screwdriver. Remove connector body. Bend locking tang back to the original position (B) before installing connector body. A-Locking Tang |S orginal Postion 74697 (O1NOVOT) 4010-5 WTS and GWS Combines Repair pxctarHamess and Connector Repair Repair (Pull Type) METRI-PACK™ Connectors Disconnect the METRI-PACK connector (A). Remove tie bands and tape. NOTE: Use JDG777 Terminal Extraction Tool’ to remove terminals. Angle top so tip slides close to the plastic socket edge Pushing inward on terminal lacking tab (D). | inser JOG777 Terminal Extraction Tool (B) 6 mm (14 in.) into connector body socket (C). Remove JOG777 Terminal Extraction Tool and push terminal (E) from socket. E Remove terminal and strip wire using JDG145 Electrician's Pliers? | AConnector B_J0G777 Terminal Extraction Teo! (C—Body Socket Locking Tab Terminal | METRV-PACK isa trademark of Deli Packard Elecic Systems | ‘inciuded 17071958 Eiectreal Repair Ki “Included in JOG155 Electical Pepa Yoo! Kit ‘M4697 (01NOVO1) 40-10-6 WTS and CWS Combines Repair PNe138Harness and Connector Repair Crimp new terminal on wire through connector using JDG144 Crimping Pliers! (A). NOTE: Terminal wil seat only one way. If terminal does rot pull into the connector body socket, check for ‘correct terminal alignment. Check to make sure locking tab on new terminal is in ‘outward position, then pull on wire until terminal locks in connector body socket. A—Crimping Pliers Included in JOGISS Electrical Repair Too! Kit Repair (Push Type) METRI-PACK Connectors Disconnect the METRI-PACK connector. Remove the tie bands and tape, Remove the connector lock (A) and mark wire colors for identification. Identity wire color locations with connector terminal letters. NOTE: Use JDG776 Extraction Too! with 56, 260, and 630 Series METRI-PACK terminals. Use JOG777 Extraction Tool with 150 Series METRI-PACK terminals. Insert JDG776 or JDG777 Terminal Extraction Too!’ (B) into connector body socket (C) pushing the terminal locking tab inward, Remove extraction tool and pull terminal (D) out of the socket. Include in JTO71058 Etectrcal Repair Kit ‘A—Connector Lock B—Extraction Too! (C—Connector Body Socket | D—Terminal Continued en net page ‘TM4697 (01NOVO1) 40-10-7 uot osonse -t.seuaver-us | WTS and CWS Combines Repair PNat99| Hamess and Connector Repair | ) Remove old contact from wite using JDG145 Universal ib ceccccarige : | Electrical Pliers,’ Included in JOG155 Etecicl Repait Too! Kit NOTE: Cable seals are color coded for three sizes of wire: + Green - 18-20 Gauge Wire —S= + Gray = 1416 Gauge Wire oe | + Blue - 10—12 Gauge Wire a 4 | IMPORTANT: The seal must fit snug over the cable i | insulation, without a gap between the 4 cable seal and the insulation. 5 Push correct size cable seal on wire. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation, Install correct size contact on wire Crimp contact (A) in position with a "W" type crimp using JDGBES Crimping Too! (8). | A—Contact a | Boteat i 5 | iz i iE = T4697 (01NOVO1) 40-10-8 "WTS and GWS Combines Repair PNet40| Harness and Connector Repair | Crimp cable seal (A) on contact using JDG865 Crimping | Too! 8). ©. cable sea! i < | Make sure locking tab (A) on the new terminal is in the | outward position. Push terminal into connector body socket until terminal locks. AnTab 2 ‘| | g| | ‘| TMd697 (OINOVO!) 40-10-9 WTS and CWS Combines Repair PuetatHarness and Connector Repair Repair CPC™, Large MATE-N-LOC™ and METRIMATE™ Pin Type Connectors Select correct size JDG140 Extraction Too!’ or JDG143 Extraction TooF to remove contact. NOTE: Allow too! push rod (C) to back out during insertion, Insert tool sleeve (A) over contact until tool bottoms. Rotate tool handle (B) to ensure release of contact locking lances. Hold too! sleeve firmly seated in connector and press q push rod button (D). Remove contact from connector. Remove old contact and strip 6 mm (1/4 in.) of insulation from wire using JOG145 Universal Electrical Pliers? Crimp new contact on wire using JOG144 Crimping 3 Pliers? 7 Spread contact locking lances and insert wire in correct, v 2 terminal of new connector. Transfer remaining wires to correct terminal of new connector. A—Too! Sleeve | B—Too! Handle (C—Too! Push Rod | D-Push Rod Button | "CPC isa wademark of AMP Inc. MATEN-LOG 1s a trademark of AMP inc ETRINATE (sa trademark of AMP Inc Included in JDG1E5 Elocincal Repalr Too! Kt and JTO? 1958 Techniian's Electnes! Repar Kit ‘included in JOGISS Electrical Repair Toe Ki ‘TM4697 (01NOVO1) 40-10-10 WTS and CWS Combines Repair Pret?| Harness and Connector Repair | Repair CPC Blade Type Connectors IMPORTANT: Move extraction tool back and forth ONLY in the direction illustrated to fully | seat tool in connector. Push tip (A) of JDG141 Extraction Too! into terminal ‘offsets until tips bottom in connector. Pull wire to remove contact from connector. Remove old contact and strip 6 mm (1/4 in.) of insulation from wire using JOG145 Universal Electrical Pliers ate Crimp new contact on wire using JDG144 Crimping Pliers’ Insert wire in correct terminal of new connector. Transfer remaining wires to correct terminal on new connector. ‘Include in JOG155 Electncal Repair Too! Kit and JTO7195B Technicians Elecincal Repair Kit ‘ncuced in JOGI5S Electrical Repair Too! Kit ‘TM4697 (01NOVO1) 40-10-11 WTS and CWS Combines Repair PNetspossible. | IMPORTANT: DO NOT pry on extraction tool. | | seam (8). Push extraction tool in connector until tool bottoms. Pull wire to remove contact from connector from wire using JDG145 Universal Electrical Pliers’ E Crimp new contact on wire using JDG144 Crimping Pliers’ Insert wire in correct terminal of new connector. | | Transfer remaining wires to correct terminal on new connector. "Included in JOGISS Electncal Repay Too! Kit ‘TM4697 (01NOVO1) Repair Small MATE-N-LOC Socket Connector Remove old contact and strip 6 mm (1/4 in.) of insulation Harness and Connector Repair Push contact (A) from wire side into connector as far as Align tip of J0G142 Extraction Too!’ opposite contact ‘A—Contact B—Contact Seam 40-10-12 —— | WTS and CWS Combines Repair PNetas 1| Hamess and Connector Repair | | Repair Small MATE-N-LOC Pin Connector — | Push contact pin (A) from wire side into connector as far | as possible. | IMPORTANT: DO NOT pry on extraction tool. Put tip of JDG142 Extraction Too!’ against locking lance | (@) anc depress lance | Pull wire to remove contact from connector body. | Remove old contact and strip 6 mm (1/4 in.) of insulation | from wire using JDG145 Universal Electrical Pliers’. Crim new contact on wire using JDG1A4 Crimping Piers i | spread contact pin locking lance and insert wire in correct terminal of new connector. Remove remaining wires and install in correct terminal of | new connector. | "included in JOG55 Electrical Repair Too! Kit ‘TM4697 (01NOVO1) 40-10-13 WTS and CWS Combines Repair PN=tAS,t Harness and Connector Repair | Repair DEUTSCH Connectors Select correct size extractor tool for size of wire to be removed: NOTE: JDG361, JDG362, and JDG363 are part of JDG359 DEUTSCH Electrical Repair Tool Kit + JDG361 Extractor Tool - 12—14 Gauge Wire + JDG362 Extractor Tool - 16—18 Gauge Wire + JDG363 Extractor Too! - 20 Gauge Wire Start correct size extractor tool over wire at handle (A). Slide extractor too! rearward along wire until tool tip snaps onto wire. = E IMPORTANT: DO NOT twist tool when inserting in ] connector. Slide extractor tool along wire into connector body until tool is positioned over terminal contact. Pull wite from connector body using extractor tool Strip 6 mm (1/4 in.) insulation from wire. Adjust selector (A) on JDG360 Crimping Too!’ for correct wire size, Loosen lock nut (B) and turn adjusting screw (C) in until screw stops. ‘A—Selector BoLock Nut (C—Adjusting Screw Included in JOG359 Electrical Repair Kit Contin on next soge Louosoa.connts 1s sevoroe ‘TM4697 (01NOVO1) 40-10-14 WTS and CWS Combines Repair Pnetas| Hamess and Connector Repair IMPORTANT: Select correct size contact sleeve or pin to fit connector body. Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).. Tighten lock nut (C). | ‘A—Contact | B—Cover CLoek Nut D—Adjusting Serew IMPORTANT: Contact must remain centered between indenters while crimping. Insert wire in contact and crimp until handle contacts stop. Release handle and remove contact. IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures. NOTE: Readiust crimping too! for each crimping procedure. Inspect contact to ensure all wires are in crimped barrel Lvossoo coors -tnrpuaverne6 | TM4697 (01NOVO1) 40-10-15 WTS and CWS Combines Repair Pueta7| Hamess and Connector Repair IMPORTANT: Install contact in correct location using correct size grommet, Push contact straight into connector body until positive stop is felt. Pull on wire slightly to ensure contact is locked in position. Transfer remaining wires to correct terminal in new ‘connector. Repair CINCH Connectors NOTE: Identity wire color locations with connector terminal letters. ‘Open connector body and slide rubber packings (A) from connector body (B) ‘A—Rubber Packings Connector Body NOTE: Beveled side of removal tool blade must face latch (A). Removal tool is stored in connector body. Install removal toot (B). Rotate tool clockwise to release latch and lift secondary lock (C). Release other latch. Remove secondary lock. AcLatch | B—Tool (C—Secondary Lock contnand on nent poe ‘TM4697 (01NOVO1) "40-10-16 WTS and CWS Combines Repair PNet4s| Harness and Connector Repair | NOTE: Bevel tip of removal too! must be up when installing into contact opening. | Removal too! can be substituted using JOG777 | WEATHER PACK Extractor.’ Insert tip (A) of removal tool into upper contact opening (8). | Hold tool fully seated and pull wire from connector body and rubber packing, | lemove old contact and strip 6 mm (1/4 in) of insulation from wire using JDG145 Universal Electrical Pliers’. ‘Crimp new contact on wire using JDG144 Crimping | Pliers® Push contact through rubber packing and into new —. connector body until fully seated. 2 Contact Opening Pull on wire slightly to ensure contact is locked in position. Install remaining wires to correct terminals in new connector. | Install secondary lock. Close connector body. Included in JTO71056 Technician’s Eloctcal Repair Kit Included in JOGI5S Electrical Repar Too! Kit TMaa97 (OTNOVOT) 40-10-17 WTS and CWS Combines Repair| Hamess and Connector Repair ‘TM4697 (01NOVOT) - 40-10-18 . WTS and CWS Combines Repair PN=150,Group 15 Wiring Harness Routing Replace Harness | IMPORTANT: Good electrical signals to instruments and long harness life depend on harness protection and specific points of support. Observe the following when replacing harnesses. | 2. Tag location of harness plastic ties as ties are removed. 3. Observe location of clamps as hamess is removed. Make sure they are in place when harness is installed. This protects hamess from damage, heat and vibration, location of the electrical circuits. Use this as an aid to repair. | | | | 4, The wiring diagrams in TM4698, Section 240 give the | 5. When installing harness, keep plastic ties far enough | from connector to prevent side stress on connector. | | 6. Always place plastic tie where there is a protective | cover over hamess. 7. Route wires in such a manner as to protect them from heat, vibration, sharp comers, from being pinched or insulation worn off. Use grommets or protective covering where necessary. ‘TM4697 (01NOVO1) 40-15-1 WTS and CWS Combines Repair Phe 1| Wiring Hamess Routing Cab Main Wiring Harness ‘TM4697 (01NOVO1) 40-15-2 WTS and CWS Combines Repair PN=152Wiring Hamess Routing | Left-Hand Main Wiring Harness ] | 5 | a — | | 74697 (01NOVOT) ~-40-15-3 "WTS and CWS Combines Repair PNets9Wiring Hamess Routing | Right-Hand Main Wiring Harness, With GREENSTAR™ | Aight Main Wan GREENSTAR GREENSTAR isa trademark of Deere & Company siezanor-0 Tasea7 (OWNOVO) 40-15-4 "WIS and GWS Combines Repair PNet54Wiring Harness Routing es | Engine Wiring Harness - Reference T4697 (01NOVO1) 40-15-5, zacsans_-in.ounao WTS and CWS Combines RepairWiring Hamess Routing M4697 (01NOVOT) 40-15-6 WTS and CWS Combines Repair PN=155Fuses, Circuit Breakers and Relays Group 20 | Specifications tem Large Relay Terminal Nut ‘Small Relay Terminal Nut Measurement Torque Torque Specitication 340 + 60 Necm (30 tb-in.) 250 + 50 Nec (22 Ib-in.) ‘TM4697 (O1NOVOT) 40-20-1 WTS and CWS Combines Repair PNeI87Fuses, Circuit Breakers and Relays Basic Operation Primary power comes into the power distribution boards from the Engine Compartment Relay Panel, located near the batteries in the engine compartment The power distribution boards provide protection, isolation and control of the following power or control systems: + Ignition Switch Power ‘+ TumBrake Signal and Light Switch Power’ ‘+ Road Light Power - Cab ‘ Road Light Power - Other Than Cab’ «Field Light Power? * Rear Light Power + Stubble Light Power + Engine Running Power * Service Power + Control Circuit Power + Wiper Power + EMIP Power (Electromagnetic Interference Protected) Used to protect circuits against voltage spikes, * Concave Position Adjust Control « Fan Speed Adjust Control IMPORTANT: Use care when mating or disconnecting connectors so that connector halves are kept in line during removal and assembly. If mating surfaces are NOT kept aligned, damage may occur to the jack screw. The power dstibuton board systoms that dea with ightng ant Rashers are discussed in TMa698 Section 240, “The power astibution board systems that deal with ighting and flashers are dlscussed inthe ighting repair sacion ‘TMae97 (01NOVO1) 40-20-2 "WTS and CWS Gombines Repair PNei88Fuses, Circuit Breakers and Relays | Power Distribution Board System Basic | | Description | ‘The power distribution boards are located in the Central | Electronics Box (CEB), located in the compartment on the left-hand side of the grain tank by the ladder landing, and | contain the fuses and control relays for most of the electrical systems on the combine. Refer to TM4698, Section 240 for systems that are powered or controlled from the power distribution boards. | Cireuit Board Replacement NOTE: Removal is the same for all circuit boards in the | Central Electronics Box (CEB). To eliminate damage from static electricity, keep all new replacement boards in their protective packaging until ready to install. IMPORTANT: Handle a circuit board with care. Hold it by its edges when installing. Itis fragile and expensive. Use grounding strap during installation of circuit board. 1. Open access door and brush out any dust. A-Cap Screw (6 used) 2, Remove cap screws (A) to remove Central Electronics | Box cover. | Contd en nent page uosareeorene tart gno%08 ‘TM4697 (01NOVO1) 40-20-3 WTS and CWS Combines RepairFuses, Circuit Breakers and Relays NOTE: Mark locations of wiring harness connectors for | re-installation into correct position. | | 3. Disconnect wiring harness connectors (A) by depressing lock release with a flat tip screw driver. 4. Loosen cap screws (B) and disconnect remaining | connectors. 5. Release latches (C). Remove Central Electronics Box to access selected circuit board | ‘A—Connectors | B—Cap Screws CHLatehes: 6. Squeeze locking clips (A) on circuit board and slide | from mounting bracket. 7. Install circuit board in reverse order. NOTE: Ensure pins to all connectors are properly seated ior to installation. AcLocking Clips ‘TM4697 (01NOVO1) 40-20-4 "WTS and GWS Combines Repair PNet60| Fuses, Circuit Breakers and Relays | Relays | Relays (A) carry large electrical loads and are controlled by switches. Relays in the central electronics box are on the main power distribution board #1, #2 and optional power distribution board #3. Relays can be replaced. IMPORTANT: Relays can be pulled out. They are made with a tight fit for good contact. To prevent damage, pull straight out. Do not pry with a screwdriver, etc. Relay | NOTE: Relay contacts have thick preform coating applied | trom the supplier. It's recommended relays be | removed and installed three times to remove preform coating on contacts for proper seating to | ‘connector. Ensure pins to all connectors are | properly seated prior to installation. Each relay is marked by function. All relays are interchangeable. ‘TM4697 (01NOVO1) 40-20-5 WTS and CWS Combines Repair PNei6t| Fuses, Circuit Breakers and Relays | Power Distribution Board Relay Identification K5—Fan Speed increase K16—Right Turn Lamps K6—Fan Speed Decrease _K17—Driving Lamps. K7—Auger Fold K18—Lott Turn Lamps Ke—Auger Unfold K19—Stubble Lamps Angle Adjust Left K15—Beacon Lamps K20—4 Field/Road Lamps ‘TM4697 (01NOVO1) 40-20-6 K21—2 Field Lamps K22—Start Interlock K23—Delayed Power CCS K24—Transmission Lockout | 25—Rear Lamps WTS and CWS Combines Repair Pret62Fuses, Circuit Breakers and Relays Engine Compartment Relay Panel Fuse Identification Crea TO | Pop peel pipette $a5 oe dibeieies & F1—Left Control Unit Power F2—Control Circuit Power F3—Light Power 3 F19—Conv. Outlet Unswitched F25—Eng) Power Power F20—Unswitched Electronic F26—Unused Control Unit | Fa—Light Power 4 F13—Unused F27—Unused F5—Light Power 2 F1g—Unused F28—Header Control Unit F6—Service Power F15—Unused Power | F7—Press. Fan Power F16—Service Lamp Power -F22—Service Light Power _—F40—Spare 20 Amp F8—Motor Power F17—Electronic Power F23—Unused Fa1—Spare 20 Amp F2—Light Power 5 F18—Light Power 1 F2t—Fuel Pump | F10—Recitculation Fan Power Power/Unused on 6081 ‘TM4697 (01NOVO1) 40-20-7 WTS and CWS Combines Repair| Fuses, Circuit Breakers and Relays = | Engine Compartment Relay Panel Relay Identification K1—Left Control Unit Power _K6-—Recirculation Fan Power K9—Electronic Power K12-Engine Control Unit K2—Control Circuit Power _K7—Unused K10—Service Lamp Power Power K3Press, Fan Power Ke—Conv. Outlet Switched K11—Header Control Unit K13—-Fuel Pump. Ka—Motor Power Power Power Power/Unused on 6031 | san Speed adjust Power ‘TM4697 (01NOVO1) 40-20-8 WTS and CWS Combines Repair PNetos| Safety Rules When Replacing Halogen Bulbs CAUTION: Halogen bulbs (A) contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying fragments. To . Turn off the light switch and allow the bulb to cool before changing bulbs. Leave the switch off until bulb change is complete. 2. Wear eye protection when changing a halogen bulb. 3. Handle the bul by its base. Avoid touching the glass. 4. Do not drop or scratch the bulb. Keep moisture away. 5. Place used bull in the new bulb's carton and dispose of properly. Keep out of reach of children. Cab Head Light Bulb Replacement and Adjustment 1 | IMPORTANT: Over tightening the screws until they | bottom out can break the head lamp. NOTE: The two center head lights use infrared bulbs, the other ones use halogen bulbs. | 4. Unscrew three serews (A) and remove head lamp (8) 2, Disconnect wiring lead (C). Clean dirt from head lamp. 3, Push in and twist retainer ring (D) counterclockwise. Bulb pulls straight out 4, When reinstalling head lamp, adjust as follows: Start with the two end screws first, then the bottom screw last. Adjust the screws unti all three tabs are flush with the panel. ‘TM4697 (01NOVO1) 40-25-1 Group 25 | Lighting | ‘A-Halogen Bulb ‘A—Screw (3 used) | B-Head Lamp | (C—Wiring Lead D—Retainer Ring | | WTS and CWS Combines Repair PN=t165Bulb Replacement 1. Remove screw (A) and bulb retainer (B). | 2, Disconnect connector (0) 3. Tum bulb (D) counterclockwise and remove. 4. Install bulb in reverse order. | a-ser0m Bulb Retainer connecter |b But Rear Discharge Light Bulb Replacement 1. Remove bulb (A) from housing (B). 2. Disconnect wiring leads (C). 3. Install bulb in reverse order. A-Bulb B-Housing C—Leads ‘M4697 (01NOVOT) | auxiliary Field and Access Door, Work Light Lighting 40-25-2 WTS and CWS Combines RepairCAUTION: Read “SAFETY RULES WHEN REPLACING HALOGEN BULBS". 1. Disconnect harness lead (A) and clean dirt from light. 2. Push in and twist retainer ring (B) counterclockwise. Bulb pulls straight out A—Harness Lead B—Retainer Ring | Grain Tank and Unloading Auger Light Bulb Replacement | | | 1. Disconnect connector (A). 2, Remove bulb from housing (B). 3. Disconnect wiring leads (C). J ] | 4. Install bulb in reverse order. A~Connector B-Housing (C—Wiring Leads ‘TM4697 (01NOVO1) 40-25-3 WTS and CWS Combines Repair PN=187| \ | Lighting | Cleaning Shoe Light Bulb Replacement | 2 Push in and twist retainer ing (B) counterclockwise | Bulb pulls straight out | | adres an |B Retainer Ring | Turn Signal and Maximum Tilt Indicator Light | Bulb Replacement | NOTE: Butb replacement for Maximum Tit only used on ‘machines equipped with the HILLMASTER 11 option, |. Tilt steering column toward driver's seat, 2. Remove four screws and remove steering column cover (A). | 9. Pu out bub socket (8), Bulb pus saint out ‘Senin column Cover ores Sosa 4. Check wiring harness connections before installing cover. | Dome and Console Light Bulb Replacement | 1. Remove lens cover by pressing sides of cover. | 2 Replace bub (A) or | 8. Replace lens cover by snapping in place. ‘A—Dome Light B—Console Light ‘TM4697 (01NOVO1) 40-25-4 WTS and CWS Combines Repair| Lighting | CommandTouch™ CornerPost Monitor Light Bulb Replacement 41. Determine which bulb is defective. 2. Disconnect wiring harness connector from back of GREENSTAR™ Display and Mapping Sensor if equipped. 8, Remove two cap screws from back of Mapping Sensor. Remove GREENSTAR™ Display assembly if equipped. 4, Remove mounting screws (A), brackat and comerpost monitor (B). 5, Remove defective bulb (C). IMPORTANT: Always handle electronic cards/components by edges to prevent damage. NOTE: Connector bodies are “keyed” for proper contact mating. Be sure contacts are in proper alignment. NOTE: If defective bulb is located under circuit board (0), | disconnect two connectors (E), carefully remove three ribbon connectors (F) and eight screws (G). Move circuit board for access to additional light bulbs. 6. Remove defective bulb by turning counterclockwise. 7. Install bulb. 8. Install comerpost monitor 9, Install GREENSTAR™ Display assembly if previously removed. 10, Install wiring harness, GommandTouch is @ trademark of Deere & Company | GREENSTAR is a trademark of Deore & Company ‘TM4697 (01NOVO1) 40-25-5 ‘A—Scrow (4 used) B— CommandTouch ComerPost Monitor Bulb D—Cireut Board E—Connector (2 used) Ribbon Connector (3 used) G—Screw (8 used) WTS and CWS Combines Repair PNst69Warning Display Panel Light Bulb Replacement 1. Remove six screws (A) attaching warning display panel and lower panel IMPORTANT: Always handle electronic cards/components by edges to prevent damage. 2. Remove screws (B) attaching circuit board to panel, | 3. Remove screws (C) attaching bulb holder, | 4. Remove defective bulb by puling straight out 5. Replace bulb in reverse order. A—Screw (6 used) |B Serew (6 used) (C—Screw (6 used) Header Float Gauge (Optional) Bulb Replacement j BD | Pull off cover (A) to replace bulb (B) behind cover. A—cover : > Bulb be sc.ovoetssst1 se-osunvee-i4 | ‘TM4697 (01NOVOT) 40-25-6 WTS and CWS Combines Repairl 1 | Other Material Number | 149513 (US) | T9474 (Canadian) 271 (LOCTITE") LOCTITE isa trademark of Loctte Com. Thread Lock and Sealer (High Strength) Group 30 | Operator’s Station Us Eliminates vibration loosening and prevents leaks. | Specifications | tom Multi-Function Handle Installation Multi-Function Handle Shoulder Bolts M4697 (01NOVO1) Measurement Torque 40-30-1 ‘Speeitication 6 Nem (53 Ib-in.) WTS and CWS Combines Repair PNet7| Operator's Station | 5 3 7 e | ACLight Dimmer Switch G—CiimeTrak™ Power Switch O—Horn Switch Steering Wheel | BoHazard Light Suiten HORadio PPark Brake Disengage -_-V—Gearshit Lever | coed Light Switen Control Pedal W_Power Mirror Switeh D—Field Light Switch jay Panel Q—Park Brake Pedal X jl @ 1 Antenna cannot be repaired. defective, it must be j replaced Se | | 2: Install base (G) n lange (F). Postion groove in flange (F) toward bottom and slide through spacer (1). Install nut (E). 4, Install (D—A). 5. Install antenna (H). ‘TM4697 (01NOVO1) 40-30-9 WTS and CWS Combines Repair PNai79CornerPost Main Circuit Board Removal IMPORTANT: If you need to replace cornerpost display the following steps need to be performed: * Record all details in C03, addresses 100—129, + Replace comerpost board and input readings starting at address 129— 100. Hf procedure is not followed and the engine hours exceed 5 hours, then the comerpost board will not allow any inputs and the board will be ruined. Disconnect connector (A) from GREENSTAR™ Display. and Mapping Sensor (B) | 2. Remove screws (C) from GREENSTAR™ Display and | Mapping Sensor mounting bracket (0). 3, Remove mounting screws (E), bracket (D), two connectors (F) and cornerpost monitor (G). 4, Remove three ribbon connectors (H), eight screws (I) and remove main circuit board (J) 5. Install in reverse order. GREENSTAR is a trademark of Doore & Comoany Operator's Station ‘A—Connector ‘B-GREENSTAR™ Monitor and Map Sensor C—Serew (2 used) D-GREENSTAR” Monitor, Map Sensor Mounting Bracket E_Screw (4 used) | F—Connector (2 used) ‘G—ComerPost H—Ribbbon Connector (3 used) Screw (6 used) | J-Main Circuit Bosra ‘T4697 (01NOVOT) 40-30-10 WTS and CWS Combines Repair PN=180| Operator's Station | 1 | Remove Header Control Module | | IMPORTANT: If you need to replace cornerpost display the following steps need to be performed: + Record all details in C03, addresses 100-129. | ‘+ Replace cornerpost board and input | teadings starting at address 129— | 100. Hf procedure is not followed and the | engine hours exceed 5 hours, then the cornerpost board will not allow any | inputs and the board will be ruined. q | | 1, Remove cornerpost and main circuit board. (See procedure in this group.) 2. Remove ribbon connectors (A) and screws (B) from header control module circuit board (C). | 3. Remove circuit board (C) and header control module. 4, Install header control module in reverse order. ‘A—Rilbbon Connector (2 used) B—Serew (6 used) (c—Cireuit Board TN4697 (01NOVO1) 40-30-11 WTS and CWS Combines Repair PNetatOperator's Station Remove Performance Monitor and Digital Tachometer Module IMPORTANT: If you need to replace comerpost display the following steps need to be performed: * Record all details in C03, addresses 100-129. ‘+ Replace cornerpost board and input readings starting at address 120— 100. If procedure is not followed and the engine hours exceed 5 hours, then the comerpost board will not allow any inputs and the board will be ruined, NOTE: Performance monitor (C) and digital tachometer A-Ribbon Connector B-Serew (6 used) (C—Pertormance Monitor D—Digital Tachometer - (D) are removed and installed utilizing the same steps, Remove comerpost and main circuit board. (See procedure in this group.) Remove ribbon connector (A) and screws (B) from circuit board performance monitor (C) Remove circuit board (C) and digital tachometer (0). Install in reverse order. ‘T4697 (01NOVO1) 40-30-12 WTS and CWS Combines Repair preteeOperator's Station Digital Tachometer Calibration A new digital tachometer from service parts must be calibrated to the correct tire size and final drive. Refer to ‘TM4698, Digital Tachometer Diagnostics. ‘TM4697 (01NOVO1) 40-30-13 WTS and CWS Combines Repair PN=183{ . 40-30-14cn ssn | Reel ForeAtt reel -—-S~Unloading Auger Drive ‘13 CLIMATRAK Solar Sensor 23—Low Speed Four Wheel (TT alserLower or Backshatt (Swing IrvOut) H4—DIAL-ASPEED™ Drive Engage (Optional) | Speed inereese/Decrease6—Unloading Augor Drive 15--Manval Ree! Speed 24-HILLMASTER I (Manual | cron Head Adjust Deck —__(OnvOtt Switen) 46—Cieaning Fan Speed Tit) Plate T-Unloading Auger Drive 17—Cigar Lighter 25-Engine Speed (Low, ‘2-HEADERTRAK Resume Inaleator Light 18—Not Used Medium and High) (Height Contol and Tit) 8—Rload Transport Disconnect 19—Not Used 25-HILLMASTER I (Engage) 2-Quiek Stop S-Header EngageFeeder 20—Cylinder Speed 27—Grain Tank Cover Open ‘CHeadertrak™ Titvtanuel House Reverser 21—Concave Ciesrance Adjust and Close | 10—Separator Engage 22—High Speed Four Wheel 28—MultiFunction Hance ‘W—Draper Belt Speed Drive Engage (Optional) | 12—Header HeightGround Pressure Control Knob Headertrak is @ adomark of Deore & Company | DIaL-A-SPEED is a trademark of Deere & Company Perret lf ‘M4697 (01NOVO1) 40-30-15 WTS and CWS Combines Repair PNet8s,Operator's Station Remove and Install CommandTouch™ Console IMPORTANT: Always handle electronic cards/components by edges to prevent damage. NOTE: Connector bodies are “keyed” for proper contact ‘mating. Be sure contacts are in proper alignment. 1, Remove screws (A). 2. Remove nut and disconnect linkage (B). 3. Remove screw (C). reach back between console base and top console assembly and pull hamess upwards to create enough slack to aid in lifting top console assembly. Pulling | harness up by the top assembly can damage harness connectors and/or | console circuit board. E IMPORTANT: When liting top console assembly, 4. Disconnect three connectors from wiring hamess (D) and remove console. | 5. Connect harness, IMPORTANT: When reassembling top console, reach under base of console and pull excess harness out through bottom. Make sure top console assembly is properly aligned with console housing while lowering into place. Forcing console down may cause circuit board damage. 6. Install console. | ‘A—Screw (3 used) Boar o—Serew Wiring Hamess 7. Conneet linkage. ConmandTouth ea radamark of Deer & Company a M4697 (O1NOVO1) 40-30-16 WTS and CWS Combines Repair PN=100Operator's Station Remove and Install Header and Separator Engage Switches 1. Lift switch (A) up far enough to depress two clips on each side and remove from socket. Switch should hang outside socke. \ 2. Remove console. (See REMOVE AND INSTALL i COMMANDTOUCH™ CONSOLE in this group.) 3 8. Note postion and remove connectors (8) from circuit i board and remove switch through top of console. 4, Install switch and connect connectors in same position ‘as removed. 6, Install console, (See REMOVE AND INSTALL. COMMANDTOUCH™ CONSOLE in this group.) Switch i Connector 3 3 | | | commandTouch isa vademark of Deere & Company eer ‘M4697 (01NOVO1) 40-30-17 WTS and CWS Combines Repair PNSta7| Operator's Station Remove and Install DIAL-A-SPEED™ and Header Height/Ground Pressure Control Switches | | 1. Remove console. (See REMOVE AND INSTALL | COMMANDTOUCH™ CONSOLE in this group.) 2. Remove three screws (A) and cover (B) from right side (bottom) of console. Remove knob (C) from top of switch Remove nut and washer from top of switch, 5. Disconnect connector (D) and remove switch (E). 7. Install console, (See REMOVE AND INSTALL COMMANDTOUCH™ CONSOLE in this group.) ‘A—Scrow (3 used) B—Cover coKnob Connector ESwiten DIAL-A-SPEED isa trademark of Deere & Conspany | CommandTouch i a trademark of Deere & Company ‘TM4697 (01NOVO1) 40-30-18 WTS and GWS Combines Repair PNer86\ Operator's Station | Remove and Install ClimaTrak™ Solar Sensor 2, Remove screws (A) and cover (8). | 3. Remove screw (C) from mounting bracket. 4, Disconnect connector and remove sensor (D). Tum |” sensor 90 degrees and remove from bracket is fe 5. Install solar sensor. 6. Install console. (See REMOVE AND INSTALL COMMANDTOUGH™ CONSOLE in this group.) | ‘A-Screw (9 used) | Bac | D—Sensor ClimaTrak is a radomark of Deere & Company | CommanaToucn is a wademark of Deore & Company —_ Remove and Install Back Light Bulbs for | DIAL-A-SPEED and Header Height/Ground Pressure Control Switches 1, Remove screws (A) and cover (B). 2. Remove bulb (D) from socket (C) 8. Install light bulb. | asta wee — oe a M4697 (O1NOVOT) 40-30-19 WTS and CWS Combines Repair PN=189Operator's Station Remove and Install CommandTouch" | Console Membrane Switches z | 1. Remove console. (See REMOVE AND INSTALL COMMANDTOUGH™ CONSOLE in this group.) Pressure Control knobs. (See REMOVE AND INSTALL | DIAL-A-SPEED™ AND HEADER HEIGHT/GROUND PRESSURE CONTROL KNOB in this group.) 3. Remove header and separator engage switches. (See REMOVE AND INSTALL HEADER AND SEPARATOR SWITCHES in this group.) 4, Peel main graphic label (A) from bezel and discard. 5. Remove screws (B) and bezel (C) 6. Remove rubber key pad (D). NOTE: Switches not used have brown plastic covers (E). Note locations for reinstallation. ‘AcMain Graphic Label B-Screw (7 used) c—Bezel D—-Rubber Key Pad | E—Plastic Cover F—Ribbon Connector (3 used) G—Mlembrane Switches § 3 | 3 | s| ConmanaTouch a rademar of Dre & Company [LOILSASPEED 10 vademar ot Deve & Company comin enon ie sssem09 | Tmae97 (o1NOVO1) 40-30-20 WTS and CWS Combines Repair PN=190Operator's Station =e 8, Move multi-function handle assembly (C) to access | circuit board. ‘A—Cap Screw (3 used) [B—Multi-Funetion Handle Wiring Hames (C—Muiti-Function Handle Assembly 9. Remove six screws (A) and disconnect ribbon connectors (B). | 10. Move circuit board assembly (C) to access ground connector. A—Screw (six used) ‘B—Ribbon Connectors (C—Cireuit Board Assembly 14, Disconnect ground connector (A). A—Ground Connector 12, Remove membrane switch assembly. 13, Install new membrane switch assembly and route ribbon harness to back of console ‘A—Membrane Switeh “TM697 (O1NOVOH) 40-30-21Operator's Station 14, Attach ground connector (A) from membrane switch to wiring hamess connector. ‘A—Ground Connector 15. Reposition circuit board (C) and retain with screws (a) 16. Attach ribbon connectors (B) to circuit board. | A Scraw (ix uses) | BLRibbon Connectors | C—Circuit Board Assembly NOTE: Make sure multi-function handle wiring harness is correctly positioned (as shown) and retained with clamp. | 17. Reposition multi-function handle assembly (C) onto Circuit board and retain with cap screws (A). 18. Attach multi-function handle wiring harness connector (8) to circuit board connector. ‘A~Cap Screw (3 used) B—Mult-Funetion Handle Wiring Hames (C—Mutt-Funetion Handle Assembly TM4697 (O1NOVO?) 40-30-22 WTS and GWS Combines Repair PNete2Operator's Station 49. Install rubber key pad (C) and plastic covers (D). 20. Install bezel (B) and retain with screws (A). ‘A~Serew (7 used) B-Bezel (c—Rubber Key Pad D-Plastic Cover F 5 21. Install new graphic label (A). 22, Install header and separator engage switches. (See REMOVE AND INSTALL HEADER AND SEPARATOR SWITCHES in this group.) 23, Install DIAL-A-SPEED™ and Header Height/Ground Pressure Control Switches. (See REMOVE AND. INSTALL DIAL-A-SPEED AND HEADER HEIGHT/GROUND PRESSURE CONTROL SWITCHES in this group.) 24. Install console. (See REMOVE AND INSTALL COMMANDTOUCH™ CONSOLE in this group.) ‘A—Main Graph Label DIAL-A-SPEED isa trademark of Desre & Company CommandTouch isa trademark of Deere & Company uosess sense Tw4697 (01NOVO) 40-30-23 WTS and CWS Combines Repair PN=t93,Ee i | Remove and Install CommandTouch™ | Console Circuit Board | IMPORTANT: Always handle electronic cards/components by edges to help | prevent damage. | COMMANDTOUCH' CONSOLE in this group.) | | | 2. Disconnect all connectors to circuit board. 3. Remove cap screws (A) from multi-function handle mounting bracket. 4, Remove screws (B) and circuit board (C) from console, 5. Carefully install circuit board, | 6. Insta mut-tunction handle 7. Connect all connectors to circuit board, 8, Install console. (See REMOVE AND INSTALL COMMANDTOUCH™ CONSOLE in this group.) | commana axon Conary ‘TM4697 (01NOVO1) 40-30-24 Operator's Station | ‘A~Serew (3 used) ‘B-Screw (5 used) C—Circuit Board WTS and CWS Combines Repair PNet9s| Operator's Station Replace Neutral Safety Switch IMPORTANT: Always handle electronic cards/eomponents by edges to help | prevent damage. 1, Remove console, (See REMOVE AND INSTALL COMMANDTOUCH™ CONSOLE in this group.) 2. Disconnect all connectors to circuit board (A). 3, Remove screws (B) to multi-function handle mounting bracket and screws (C). Carefully remove circuit board 4, Remove screws (D). Disconnect connector and remove switch (E). 5. Install switch 6. Install circuit board and multi-function handle. 7. Connect all connectors to circuit board. | 8. Install console. (See REMOVE AND INSTALL | COMMANDTOUGH™ CONSOLE inthis group.) A—Cireuit Board B-Serew (3 used) | (C—Serew (5 used) ‘D—Serew (2 used) Neutral Safety Switch CommandToush i a tademark of Deere & Company scovosnss sno —r-amavor ‘TM4697 (01NOVO1) 40-30-25 WTS and CWS Combines Repair PNeI95Replace Mini Harness | IMPORTANT: Always handle electronic cards/components by edges to help prevent damage. | 7+ Remove console, | 2. Remove screws (A) and cover (B) 3. Remove two sockets (C) from bottom cover and two light bulbs (D). 4. Disconnect wire leads (E) from cigarette lighter. 6. Remove three cap screws (F) from multi-function handle mounting bracket and screws (G) from circuit board (H). Carefully remove circuit board, E 5. Disconnect all connectors from circuit board, 7. Remove sockets and bulbs (|) 8. Disconnect remaining connectors and remove hamess v. 9. Install harness. 10. Install bulbs. 11. Install circuit board and multi-function handle, | 12. Connect all connectors to circuit board, 13. Install cigarette lighter. 14, Install cover. | 15. install console. A—Screw (3 used B-Cover (C—Socket (2 used) D—Bulb (2 used) E—Wire Leas F_Screw (3 used) G—Serew (5 used) HoCircuit Boara Sockets Jatin Harness TM4697 (O1NOVO1) 40-30-26 WTS and CWS Combines Repair 6 7Operator's Station Remove and Install Multi-Function Handle 1. Remove console. (See REMOVE AND INSTALL COMMANDTOUCH™ CONSOLE in this group.) 2. Disconnect connector (A) from circuit board. | 3, Remove J-clamp (B). | 4. Remove shoulder bolts (C) and spring (D) from arm (E). 5, Remove multifunction handle (F) from top of console. 6. Install multi-function handle through top of console. 7. Apply TY43513 Thread Lock and Sealer to shoulder bolts (C); then install shoulder bolts and attach spring {D) to arm (E). Tighten to specifications. ‘Mutt-Funetion Handle installation—Speecification Mutt-Function Handle Shouider Botle—Torque Nem (ston) 8. Install harness correctly using J-clamp (B). 9. Connect connector (A) to circuit board. 10. Install console. (See REMOVE AND INSTALL COMMANDTOUCH™ CONSOLE in this group.) ‘b—Connector B-s-Clamp (C—Shoulder Bolt (2 used) | D-Spring E-Arm F—Mult-Funetion Handle CommandTouch is trademark of Deere & Company Sees TM4697 (O1NOVO1) 40-30-27 WTS and GWS Gombines Repair PNat97Operator's Station Remove and Install Start Switch | | | 1. Remove four screws and cover (A). | 2. Unplug connector (B) and single wire (E) from switch, making certain to identity each connector for installation on new switch. | | 3. Remove lock nut (C) and switch (D). 4, Install switch, NOTE: A new switch will use the same key as the old ‘one. This key also works forthe door lock 4 A-cover Connector (C—Lock Nut D—Switeh EWire TW4697 (O1NOVOT) - 40-30-28 WTS and CWS Combines Repair PNe108| Operator's Station | Remove and Install Starting Aid Switch 1. Remove cover (A). | 2. Remove guard (C) and cap (B) from switch by tuning | cap counterclockwise, 3. Pull starting aid switch (D) out through hole from inside cf housing, Switch cannot be repaired. Defective switch must be replaced. 4, Disconnect wire lead connector (E). 5. Connect connector. 6. Install switch through hole inside of housing. Place cap (B) inside of guard (C) and tighten cap by turning clockwise, 7. Install cover. ‘A—Cover BCop c—Guard D—Switeh Connector ry acovoeea se -ss-cowavor-1 | Remove and Install Turn Signal/Side Finder Light Switch See DISASSEMBLE AND ASSEMBLE STEERING COLUMN in Section 60, Group 05. ‘TM4697 (01NOVO1) 40-30-29 WTS and CWS Combines Repair PN=i99Remove and Install Horn Switch Remove four screws and cover (A) 2. Remove cap (B) from switch (C). 3, Remove horn switch (C). Switch cannot be repaired. Defective switch must be replaced. 4. Disconnect wiring lead at connector (D) [5 ta swe | 6. Connect connector. 7. nt cover E ... es (Hom switeh D—Connector Operator's Station | Remove and Install Mirrors | 1. Disconnect eonneetor (A) from mirtor 2. Loosen cap screws (8) 3. Slide mirror off mounting post (C) 4, Inspect mirror, replace as necessary | 5. Slide mirror onto mounting post (C) | 6. Tighten cap screws (B) | 7. Connect connector (A). TM4697 (O1NOVO1) A—Connector Cap Screw (2 used) ‘C—Mounting Post 40-30-30 WTS and CWS Combines Repair PN=200| Operator's Station | Remove and Install Mirror Switch 1. Remove screws (A) attaching overhead panel. ASerew (6 used) uoversonoees 9. oeBoraus 2. Disconnect connectors (A) from switch (B). | 8. Press in clips on sides of switch (B) and remove by | pushing through front of overhead panel 4, Install switch (B) into overhead panel. 5. Connect connectors (A). A—Connectors B-Switen 6, Install overhead panel and screws (A). ‘A~Serew (6 used) ‘TM4697 (01NOVO1) 40-30-31 WTS and CWS Combines Repair PNazo1| Operator's Station ‘TM4697 (01NOVO1) [ 40-30-32 WTS and CWS Combines Repair PregoeGroup 35 | Sensors and Switches _ ir | | Other Material | Number Name Use Ty9975 (US) TEFLON Pipe Sealant ‘Seal threads to prevent escape of | liquid or gases. | Shaft Speed Sensor Locations a | T > a | LW | —\\ 4] iT | | AL —— i SS { JD | So — cy ai | : ® § = . 2 am, Gir, Mr, | | A-Ctaning Fan b-oyinder Speed Fender Howe Backat | | ee eee ‘TM4697 (01NOVOT) 40-35-1 WTS and CWS Combines Repair PNe203Sensors and Switches | Shaft Speed Sensor Locations | ® ® | Lottand Side ‘ATallings Elevator (C—Grain Elevator Grain Separator FPower Separator B-Auger Conveyor (0—Straw Chopper ‘TM4697 (01NOVO1) 40-35-2 WTS and CWS Combines Repair PNe2os| Sensors and Switches Remove and Install Conveyor Auger, Tailings | Elevator, Grain Elevator and Grain Separator — | Sensors | NOTE: The following procedure applies to auger conveyor, tailings elevator, clean grain elevator and separator sensors. 1. Remove debris buildup and disconnect connector (A). 2, Remove screws (B) and sensor. 8, Remove two sorews (C) and magnet. — 4, Install sensor. 5. Connect connector (A). ‘A—connector B-Serew (2 used) (C—Serew (2 used) | Remove and Install Cleaning Fan, Cylinder Speed and Feeder House Backshaft Speed | Sensors NOTE: The following steps also apply to cleaning fan, cylinder speed and feeder house backshatt speed sensors. Disconnect connector (A). Tum sensor (B) counterclockwise and remove. {Install sensor. Turn sensor clockwise until it contacts tone wheel (C). Back sensor off 1/2 turn counterclockwise. | 4. Connect connector (A), ‘M4697 (01NOVO1) 40-35-3 ‘A—Connector B—Sensor ‘c—Tone Whee! WTS and CWS Combines Repair pNe205‘Sensors and Switches | | Remove and Install Straw Chopper Sensor 2, Remove screws (B) and sensor from bracket. | 3, Remove sorews (C) from magnetic collar, | 4 Install collar using screws (C) | 5. Install sensor to bracket using screws (B). 6. Connect sensor hamess connector (A) | ‘A-Connector Seren @ used) (C-Scrow (2 used) E Remove and Install Grain Tank Sensor i | | 1. Disconnect connector (A), | 2. Remove attaching hardware | 3. Remove sensor (B). | A—Connector | B-Sensor As ovoKosns¢0 19. ‘M4697 (01NOVO1) 40-35-4 WTS and CWS Combines Repair PN=206| ‘Sensors and Switches Remove and Install Tailings Sensor | CAUTION: Disconnect hamess connectors before servicing tailings sensor(s). NOTE: There are two sensors located on the tailings elevator, Inside sensor is the master and outside is the slave, 1. Disconnect harness connectors (A) from each sensor. 2, Remove spring (B). ‘A—Connector (2 used) 3, Remove sensors (C). B-Spring C—Sensor (2 used) | 4, Install sensors. 5. Install sensor by aligning tabs on sensor with holes in elevator. Install retaining spring. | Remove and Install (Shoe/Separator) | VisionTrak™ Sensors | 1. Disconnect connector (A). 2. Remave screws (B) and remove sensor (C). 3. Install sensor. A—Connector | BSerew (4 used) (c—Sensor UisionTrak is @ trademark of Deere & Company saqureonss recount ‘TM4697 (01NOVO1) 40-35-5 WTS and CWS Combines Repair PN=207Sensors and Switches Remove and Install (Return to Cut and Tilt) Header Height/Ground Pressure Control Sensors 1. Remove shields (A) as necessary, 2. Remove attaching hardware and clip (B). 3. Disconnect connector (C} 4, Remove attaching hardware and sensor (0). on i ee Hts i eloer ae nee ereaee ‘TM4697 (01NOVO1) 40-35-6 WTS and CWS Combines Repair PN=208| Sensors and Switches 5. Align key (A) with notch (B) and install sensor. | | 6. Install attaching hardware. 7. Install shields, Ankey BoNotch | Remove and Install Coolant Temperature Sensor | Ay CAUTION: Coolant may be hot. Wait until ee aii, 1, Slowly loosen radiator cap 74697 (01NOVO1) 40-35-7 "WTS and CWS Combines Repair PN=209Sensors and Switches l 2, Drain coolant at radiator drain (A) and engine block temperature sensor. 3, Close radiator drain (A) and engine block drain (B). 4, Close radiator cap to prevent contamination from entering coolant system, ‘A—Radiator Drain Engine Block Drain 5. Disconnect sensor connector (A). 6. Tur sensor (B) counterclockwise using a wrench ONLY on the hex portion of the sensor. Sensor cannot be repaired. If defective, it must be replaced. 7. Apply TY9975 pipe sealant with TEFLON to threads of sensor. Tum sensor (B) clockwise using a wrench ONLY on the hex portion of the sensor. 8. Connect connector (A) to sensor. 9. Open radiator cap and fill radiator with coolant to capacity, 10. Close radiator cap, ‘TM4697 (01NOVO1) 40-35-8 drain (B) until coolant level has drained below coolant BS ‘A—Connector B—Sensor ‘Sensor ouosusraonsa -sanacnss | WTS and CWS Combines Repair PNaetoiu | Remove and Install Coolant Temperature Sensor | 4. Disconnect wiring lead connector (A). | 2. Remove sensor (B). Sensor cannot be repaired. If defective, it must be | replaced. | 3. Apply pipe sealant TEFLON’ to threads of sensor. install sensor (8). \ ‘A—Connector B—Sensor TEFLON is registered trademark of the DuPont Company. Remove and Install Fuel Level Sensor 1, Clean area around fuel sensor to avoid contaminating fuel supply when sensor is removed, 2, Disconnect connector (A) to fuel sensor. | NOTE: Observe how float arm is positioned in relation to | fuel tank. This will simpliy sensor installation. | 3. Remove screws (B), fuel sensor {C) and gasket (0). | Sensor can not be repaired. If damaged, it must be | replaced. 4, Install fuel sensor using new gasket (D). Guide fuel ‘sensor (C) through top of fue! tank with float arm positioned toward center of tank. Install five screws (B). 5. Connect connector (A) to fuel sensor. ‘TM4697 (01NOVO1) 40-35-9 Sensors and Switches ‘Sensor A—Connector | B-Serew (5 used) (C—Fuel Level Sensor D—Gasket | WTS and CWS Combines Repair pneeitSensors and Switches | Remove and Install Park Brake Switch 1. Disconnect connector (A). 2. Loosen retaining nut (B) and remove switch (C). ie 3. Switch cannot be repaired. Defective switch must be ie replaced, fal | 3 if | 4 install switch, 3 5 2 5. Connect connector. &| Connector | Retaining Nut c—Switeh AG ove 26+ 1e-c2nnon-ts Remove and Install Air Filter Restriction Switch 1. Disconnect connector (A). 2, Remove switch (B). Switch cannot be repaired. It must be replaced. E | | | 3. Install switch (8), Be | 4. Connect connector (A), i ‘A-Connector eoSwich | | | | oe | s seovonnosts ie ceaneu | TMA697 (O1NOVO3) 40-35-10 "WTS and CWS Combines Repair PNeai2| | \ ‘Sensors and Switches | | Remove and Install Engine Gear Case | Temperature and Pressure Switches | | 1. Disconnect wiring lead connectors (A). 2. Remove temperature (B) and pressure (C) switches. ‘Switches cannot be repaired. If defective, they must be replaced. 3, Install switches (B) and (C) using new O-rings. 4, Connect wiring lead connectors (A). Temperature Switch (C—Pressure Switch pc.ovossnse? —se.0nuNso-UT Remove and Install Hydro Charge Pressure Switch 1. Disconnect wiring lead connector (A). | 2. Remove switch (B). Switch cannot be repaired. If defective, it must be replaced. 3, Install switch (B) using new O-ring 4, Connect wiring lead connector (A). ‘A—Connactor B—Switen ‘TM4697 (01NOVO1) 40-35-11 WTS and CWS Combines Repair PNaatsSensors and Switches 7 = Remove and Install Hydraulic Reservoir Temperature Sensor { 1. Drain reservoir to level below sensor. 2, Disconnect connector (A). 3. Remove sensor (B). Sensor cannot be repaired. If defective, it must be replaced, 4, Install sensor (B) using new O-ring. 5. Connect connector (A). A—Connector Temperature Sensor 6. Fill reservoir with recommended oll ; = Remove and Install Engine Oil Pressure Switch 1. Disconnect wiring lead connector (A). 2. Remove switch (B). Switch cannot be repaired, If | defective it must be replaced. 3. Apply pipe sealant TEFLON to threads of switch and install switch (B). 4. Connect wiring lead (A), A—Connector | B_Pressure Switch TEFLON isa registered trademark ofthe DuFent Company. Ag.ouocon 369 1. e2s00-1 ‘TM4697 (01NOVOT) 40-35-12 WTS and CWS Combines Repair PNeaid| Sensors and Switches Remove and Install Service and Cleaning Shoe Light Switch NOTE: Procedure to remove and install all switches is the same. | 1. disconnect connector (A 2. On face of mounting bracket, remove nut (B) from switch | 3. Remove switch (C). Switch cannot be repaired. | Defective switch must be replaced. 4, Install switch, | 8. Connect connector. | ‘A—Connector Nut ‘Switch ‘TM4697 (01NOVO1) 40-35-13 WTS and CWS Combines Repair PNe2Is‘Sensors and Switches | T4697 (01NOVOT) "40-35-14 "WTS and GWS Combines Repair PNe216| Specifications | | Windshield Wiper Main Arm Lock | Nut ce | Remove and Install Wiper Motor NOTE: Make sure wipers are in the parked position | before starting removal procedures. |. Remove cap ews A and sun vir) A—Cap Serew (3 used) B-Sun Visor Measurement Torque Group 40 Wiper ‘Specification 48.Nem (164 ton) a | | 2. Remove front headliner (A) from cab by pulling back and down on front edge of headliner to clear tabs (B). | ‘A—Tab (5 used) B-Headliner | 3. Disconnect harness connector (A). A-taess Connector ‘TM4697 (O1NOVOT) 40-40-1 WTS and CWS Combines Repair PN=2i7| 4. Remove lock nut (A) and disconnect linkage from |” motor shatt. 5. Remove cap screws (B) and wiper motor. 6. Inspect all parts for wear and damage, replace as necessary. A—Lock Nut B—Cap Screw (3 used) 7. Install motor and retain with cap screws (A). 8. Install wiper linkage to motor and retain with lock nut (8). ‘A—Cap Screw (3 used) Lock Nut 9. Connect harness connector (A). ‘A-Harness Connector 10. Connect front headliner (A) in cab by pulling back and lifting up on front edge of headliner to clear tabs (B). ‘A—Heasliner B—Tab (6 used) e 5 L _ . TM4697 (01NOVO1) 40-40-2 WTS and CWS Combines Repair PNeoie+11. Install sun visor (A) and retain with cap screws (B). ‘A—Sun Visor B—Cap Screw (3 used) ‘TM4697 (01NOVO1) 40-40-3 WTS and CWS Combines Repair PNeoteWiper | Agjust Long Windshield Wiper |. Operate wiper, mark extremes of wiper stroke with tape on windshield near vertical center of two blade holder. 2. Park wiper and shut it off. If tape markings are not equally spaced from edges of windshield, adjust in increments of 2.5 degrees (4.4 mm) [1.7 in.] at center of two blade holder by repositioning main wiper arm on outer pivot shaft 3. To reposition main wiper shatt: a. Flex lower section of main wiper arm (A) out away from windshield and install a pin through small hole (8) in lower section of main wiper arm near upper pivot shatt. 'b. Remove lock nut from main upper arm pivot and pry assembly off pivot shaft . Insert a 3/8 in. punch in pivot hole on front side of main arm. Drive out splined driver cone that is in cavity on back side of main arm and install it onto pivot shaft. d. Use marking tape as reference point and install main arm loosely on pivot shatt. Position as desired | in relation to tape before seating it on splined driver. 4, Install lock nut on pivot shatt and tighten to specification Specification Windshield Wiper Main Arm Lock Nut—Torque. 18Nen (4 sn), 5. Flex lower section of main wiper arm out and remove pin installed through lower arm below the pivot. 6. Adjust park as follows: a. Remove front section of headliner. b. Loosen two screws that go through slots in white | plastic cap on back of wiper motor. L — ‘TM4697 (01NOVOT) 40-40-4 A—Main Wiper B—Small Hole scouomoare ssosanoni2 | WTS and CWS Combines Repair PN=220ie : Wiper ol |. Use a wrench on hexagon stem in center of plastic cover and slowly move plastic cover a small amount. Try wipers. Repeat adjustment as desired, 7M4697 (O1NOVO1) 40-40-5 WTS and CWS Combines Repair Naz2i| L | Remove and install Windshield Washer ‘TMA697 (01NOVO1) Wiper WTS and CWS Combines Repair PNeo22Wiper | A—Nozzle (2 used) F—Grommet ey == oot | Score ang ste ee Bmp (ues | eons | 2. Inspect parts. Replace as needed. scap ko West Res 3. | NOTE: Pump cannot be repaired. If defective, it must be replaced. iter her Install washer parts. N-Flange Nut (4 used) Screw Grommet o—Pump TM4697 (01NOVOt) 40-40-7 WTS and CWS Combines Repair A 23Wiper | Twd697 (01NOVO1) — 40-40-8 : WTS and CWS Combines Repair Pn:| Group 45 | Alternator | Specifications | tem Measurement Specification | | temator Mounting Cap Seren Torque 28 6 Nem | (21 £4 lb-ft) i | 5/16 in, Attemator Nut Torque 11.Nem | (97 Ib-in.) {V4 in. Alternator Nut Torque 41.Nem | | (97 Ib-in) | une ooes -sporausorut | John Deere Engine Accessories—Alternator Repair—Use CTM77 For complete repair information the component technical manual (CTM) is also required, Use the component technical manual in conjunction with this combine manual. scquotsees sami | TM4697 (01NOVO1) 40-45-1 WTS and CWS Combines Repair PN=22511—Cap Screw 28 = 6 Nem | eo stony ‘M4697 (01NOVO1) Altemator Alternator and Fan Drive—8.1 L Engine | ‘1—Cap Screw (6 used) 80+ 16 12—Washer ‘24—Washer weer aoa i here (ate Henoer oy Space ine pa coer {echuley 77215 hm 67 Beatap Sr ves 61 = fret wing Aevmny Ty ‘ama |EeapStrwtoS ohm 7—themmee 2-Meshor (sa) [Serre {bap See Seer Shen Tenaonr esienn ioeet | oeep See soot da—ampreetor cremate’ $0 101m BroBraeet Sc erecket orerieey 2a Cap Screw @ ed 61+ MoGap Stew (used) 34-7 10 Sep baer ‘aim Goo rem ese sty Cop Sut 4-8 tm (90 © 6 fost) 40-45-2 35—-Cap Scrow 34 + 7 Nem 25 =5 lb-ft) 36—Support 37-0-Ring 38--Cap Screw (4 used) ‘38-Washer (4 used) | 40—Pulley ‘41—Bracket 42—Cap Serew (4 used) 300 + {60 Nem (221 = 44 bt) 43—Cap Screw (2 used) 101+ 20'Nem (7515 lb) WTS and CWS Combines Repair PNe226Alternator ‘TM4697 (01NOVO1) 40-45-3 WTS and CWS Combines Repair enna?| Alternator and Fan Drive—6.8 L EngineAlternator | acne Bracket L—Connector R-sheave Cover HoWwasher N—Bushing c—sereen cep Screw 28 6 Nem (202 N—Bracket Doseal ‘st Bushing U—Washer Alternator soot Pocap Screw VNU 77 = 15 Nem (67 211 F-Spacer K—Washer Vb-tt) | | M4697 (O1NOVO) 40-45-5 WTS and GWS Combines Repair PNa229| | l : a Altemator | | | | a | 4 a 6.8L Fan Assembly = | ‘TM4697 (01NOVO1) — 40-45-6 WTS and CWS Combines Repair PN=230| Alternator [ 5 —cap sero 6 ves) 2-cap serew (4 ans) Spacer iter EieapSeew (¢ wed) becap Screw | Sey oe ehh on ect seat Sea oce SEE cern vane) eeu Berm (2 ng) ZT —Tenloer sre See toons) 7Supper foeapscew Se—ruley Sunper Toe Housing ——«—Saeup Sera (2 ves) S8—Nut une) ieee Sow eons) macaw {oman Seon (2 oe) oat Bo supper Siasteee Soy focpuney Rrewpcrw uted) Salar outer Wreapserew (tans) 22—Suppert Remove and Install Alternator 1, Turn and remove handle (A) from post to disconnect, battery ground. A-Handle in idler to release tension on belt. Remove belt (B) | 2. Insert a 1/2 inch drive breaker bar (A) into square hole | | from alternator. A—Breaker Bat BoBelt 8. Remove nuts, lock washers and wires (A). A—Wire (2 used) | M4697 (01NOVO1) ‘40-45-7 EG ROD Te 8 sooo WTS and CWS Combines Repair PNe2atAlternator | 4. Remove cap screw (A) and cap screw and nut (8) to remove alternator. 5. To repair alternator, refer to CTM77. | | 6. Install aternator and retain with previously removed | hardware (A) and (B). 7. Tighten cap screw (A) to specification Specitication Aternator Mounting Cap Scren— Torque 28=6Nem | (t= 4 bt A—Cap Screw Cap Serew and Nut 8. Install wires (A) and retain with previously removed hardware. Tighten nuts to spectfication. Specification 5116 in. Atemator Nut—Torque 11.Nem (97 tein) 14 in, Aternator Nut—Torque 45 Nem (97 toan) ‘A—Wire (2 used) 9. Insert a 1/2 inch drive breaker bar (A) into the square | hole in idier to release tension on the belt. Install belt | (B) and remove breaker bar. 10. Install belt (B). ‘A=1/2 Inch Breaker Bar Bae M4697 (O1NOVO1) 2 40-45-80 WTS and CWS Combines Repair puczie| Group 50 | | Starting Motor Specifications | tem Messurement speciation Starter Motor Installation Cap Screws Torque 47 Nem (35 Ib-tt) John Deere Starting Motor Repair—Use cTM77 For complete repair information the component technical manual (CTM) is also required. Use the component technical manual in conjunction with this combine manual. Remove and Install Starting Motor 1. Tum and remove handle (A) from post to disconnect | battery ground, 2, Remove engine access panel. 3, Clean area around starter. A-Handle continued on net page ‘TM4697 (01NOVO1) 40-50-1 WTS and CWS Combines Repair PN=233Ll Starting Motor | 4. Disconnect wires (A) and wire (B) to relay. 5. Remove cap screws (C) and lit out starter. Use JDE8O Wrench to remove the bolt behind the starter. 6. To repair starting motor, refer to CTM77. | 7. Position motor and install three cap screws (C). | Tighten to specification. | Starter Motor installation—Specification Cap Screns—Terque 47 Nem (65 tot) 8. Connect wires (A) and (B), (C—Cap Screw (3 used) | 9. Install engine access panel 10. Connect battery ground Remove and Install Starter Relay 1, Tum and remove handle (A) from post to disconnect battery ground, ACHandle ‘TM4697 (01NOVO1) — 40-50-2 WTS and CWS Combines Repair PNe2a4Starting Motor | 2. Remove engine access panel, 3, Clean area around starter relay. 4, Remove cap screws (A) to remove cover (B). 5, Remove nuts (C) to remove wires from starter relay. 6. Remove cap screws (D) to remove starter relay. Relay cannot be repaired. If defective, it must be replaced. 7. Install relay using cap screws (0) 8. Connect wires using nuts (C). 9. Install cover (B) using cap screws (A) 410. Install engine access panel 11, Connect battery ground. ‘A—Cap Serew (2 used) Cover (C—Nut @ used) D—Cap Serew (2 used) _ auwensies reeuuee | ‘TM4697 (01NOVO1) 40-50-3 WTS and CWS Combines Repair PNs295,l Starting Motor TM4697 (01NOVO1) 40-50-4 WTS and GWS Gombines Repair PN=236| Group 55 | GREENSTAR Components Measurement Speciation Mass Flow Sensor-io-impact Plate Torque 30 Nem | Nuts (22 tb-tt Mass Flow Sensor-to-Transiion ‘Torque 30 Nem Housing (22 Ib-t) Remove and Install GREENSTAR Mass-Flow Sensor 1. Retain grain tank covers in the open position and disconnect linkage from loading auger. Lower loading auger. 2. Disconnect connector (A) from wiring harness. 3, Remove two wing bolts (B) and cover. ‘A~Connector ‘Wing Bolt (2 used) . 7 4 Remove nuts (A) and sensor assembly from insite of rounng | nemnez ws | | | E | | ie | / M4697 (01NOVO1) 40-55-1 WTS and CWS Combines Repair PNaoa7impact plate (0). ‘AcNut 2 used) '—Washer (C—Mass Flow Sensor impact Plate Tighten nuts (A) to specification, 6. Install mass flow sensor (C) onto impact plate (D}. GREENSTAR Components al 5. Remove nuts (A), and mass flow sensor (C) from | z i| | | ‘Specification | ass Few Sensor sompact | | Pate nute—Torwe 20 en | ein | acaiut@ uses) Washer 2 Maes Flow Sensor 3| D—impoct tate a] e 3 8 al | | | | M4697 (01NOVO) . : 40-55-2 ~~ WTS and GWS Combines Repair PN=208| GREENSTAR Components | NOTE: Make sure clearance between inside edge of impact plate to transition housing is equal along entire length of impact plate. 7. Install mass flow sensor (B) into transition housing and tighten nuts (A) to specification Specification 3 Mass Flow Sensorto-Transiton a | Housing —roraue 30.Nem 3 (22 et) ig 2 | ‘A=Nut (2 used) Sensor Assembly NOTE: Make sure wiring hamess rests in cover notch before tightening wing bolts 8. Install cover and wing bolts (B). | 9. Connect connector (A). | 10. Raise loading auger and connect grain tank linkage. ‘A~Connector ‘B_Wing Bot (2 used) BS ie 5 ouosssonors -t-csansoro6 | TM4697 (01NOVO1) 40-55-3 WTS and CWS Combines Repair PN=239Remove and Install GREENSTAR Paddle Wheel | 2. Pull paddle whee! (A) off motor shaft. 4, Reinstall cover on moisture sensor. | ‘A—Padlle Whee! | Remove and Install GREENSTAR Moisture | Sensor 1-4. Open right-hand front gull wing door. | I | 2. Disconnect connector (A) and remove wiring harness | trom clamp. 3, Carefully press in on tabs (B) and remove cover (C) from moisture sensor — SFE eo aol | | : | | Continued on next _2uowe96.0900060_~19-12UL0 : ‘TM4697 (01NOVO1) 40-55-4 WTS and CWS Combines Repair er)GREENSTAR Components | 4. Reve cap sre (A) rom bracket lao a of ‘A~Cap Screw (2 used) | 5. Remove nuts, and round head screws (A) from sensor. Slide sensor from between top and bottom brackets. | ‘A—Cap Scrow (2 used) NOTE: Do not tighten hardware at this time. 6. Set moisture sensor on 45° bracket and install hardware (A) and (B). NOTE: Make sure that the moisture sensor rests tightly against the elevator before tightening sensor ‘mounting hardware. 7. Position moisture sensor on the top of upper 90: bracket and install cap screws (C). 8, Tighten lower sensor mounting hardware, A-Hardware ‘8 -Hardware (C—Cap Serew (2 used) ‘TM4697 (01NOVO1) 40-55-5 WTS and CWS Combines Repair PNeaatI GREENSTAR Components 8, Slide bracket (A) out so that surfaces (B) rest tightly against elevator. 10. Tighten nuts (C) ‘A—Bracket | B—Surface (C—Nut 2 used) 11. Connect connector (A). E 12, ign cover (C) and press io latches on moisture sensor (8) | ‘A—Comector B-Moisture Sensor Latches (7 used) cHcover | | TN4697 (O1NOVOT) ” 40-55-6 WTS and CWS Combines Repair Pate| GREENSTAR Components | Remove and Install Position Receiver | 1. Disconnect harness (A) from position receiver. | | 2. Lift connector latch (B) to remove position receiver. . Inspect position receiver for damage. Replace as needed. 4. Install position receiver by aligning pins (C) with slots {O) in position receiver mounting bracket and snapping into place. 5. Attach harness (A) to position receiver. A-Harness | Boonnector Latch } Pin | D=Mounting Bracket Slots acouosese tes se-raann-tn | TM4697 (O1NOVO1) 40-55-7 WTS and CWS Combines Repair PNa2aGREENSTAR Components T4697 (O1NOVO1) 40-55-68 - WTS and CWS Combines Repair Nats| 4 Contents Page Page Group 05—Transmission and Differential Inspect Fixed Swashplate 50-15-20 | Other Material -80-05-1 Inspect Piston Slipper 50-15-21 Specifications... 50-05-2 Inspect Piston Retainer 50-15-22 Remove and Repair Shiter Forks and Inspect Cylinder Block 50-15-23 Shifter Cam... 50-05-3 Inspect Bearing Plate 50-15-23 | install Shitter Forks and Shifter Gam 50-05-5 Inspect Valve Plate. 50-15-26, Remove and Install Transmission Lube Inspect Bearing and Race “50-15-28 Pump: .50-05-7 Inspect Servo Piston 1150-15-28 Remove and install Suction Screen 50-05-9 inspect Drive Shaft ...... :50-15-29 | Remove Transmission 50-05-10 Replace Cylinder Block Spring . “5015-29 | Transmission Components 50-05-14 Assemble Motor 50-15-20 Transmission Recondition 50-05-18 Remove and Install Motor Valve Block | Disassemble and Repair Transmission... . 50-05-16 (Manifold) 50-15-37 ‘Assemble Transmission 50-05-24 Repair Motor Valve Block . {50-15-40 Install Transmission 50-05-27 Remove Hydrostatic Pump 50-15-41 Remove and Install Gearshitt Lever and Disassemble Hydrostatic Pump 1150-15-43 | Linkage 50-05-30 Assemble Hydrostatic Pump “50-15-56 Agiust Gearshift Linkage “50-05-82 Replace High-Pressure Line Center Pivot O-Rings ++ 8045-70 | Group 10—Single Reduction Final Drive Disassemble and Assemble End Cover... .50-16-71 | Essential or Recommended Tools. 50-10-1 Repair Control Valve. ‘30-15-72 | Service Equipment and Tools 50-10-2 Install Hydrostatic Pump 50-15-73, Serer Matra " So103 Reme/and ntal Chrge Bump... S048 74 | Specifications 50-104 Repair Charge Pump : 50-15-75 Romove and Install Final Drive 50-10-5. Remove and Install Contol Gable *'50-15-76 Disassemble and Assemble Final Drive... 50-10-98 Adjust Hydrostatic Neutral Linkage . 50-15-77 Adjust Spindle Bearing (Preferred Method) .. 50-10-19 Adjust Displacement Control Valve Neutral. ..50-15-78 Adjust Spindle Bearing (Altemate Method) .. 50-10-18 Start-Up Procedure After Hydrostatic System Repair. 50-15-80 Group 15—Hydrostatic System Essential or Recommended Toots ..5045-1 Group 20—Cam Lobe Motor Service Equipment and Toots 50-15-1 Essential or Recommended Tools 50-20-1 Other Material. 50-15-3 Service Equipment and Tools . 50-20-4 Specifications 1150-15-4 Other Material 50-20-6 Serial Number Plate 50-15-86 Specifications 50-20-7 | Clean Hydrostatic Motor and Pump 50-16-6 Flushing Cam Lobe Motors... 50-20-8 Flushing the Hydrostatic System “30-15-7 Remove Cam Lobe Motor 50-209 Remove and Install Hydrostatic Motor 50-15-8 instal Cam Lobe Motor 5150-20-11 Disassemble Hydrostatic Motor 50-15-10 Remove and install Gam Lobe Motor Inspect Parts ‘50-15-16 Control Valve. . 50-20-12 Lack of Lubrication 50-15-17 Disassemble and Assemble Gam Lobe Motor Abrasive Contamination 50-16-17 Control Valve 50-20-14 Cavitation 50-16-18 Remove and instal Over Speeding 50-15-18 Steering yoke~2 speed 50-20-16 | Inspect Shatt Seal 50-15-19, | Inspect Thrust Plate 50-15-20 TM4697 (01NOVO1) 50-1 WTS and CWS Combines Repair Section 50 Power Train Repair |Contents Page Disassemble and Assemble Pivot Pins, Bushings, and Seals 50-20-23 Remove and Install Solenoid Valve and Valve Block -50-20-26 Remove and Install Displacement Control Valve oe 50-20-30 Remove and Install Cam and Piston Carrier a 50-20-33 Remove and Install Stack Valve Seals 50-20-38 | Remove and Install Axle Bearings and Seals — 50-20-42 Group 25—Tires and Wheels Essential or Recommended Tools. 50-25-1 Service Equipment and Tools «5025-2 Specifications . ae - 50-25-2 Tire Identitication. 50-25-3 Service Tires Safely 50-25-4 Using Liquid Weight . 50-255 Remove and Install Tire 50-25-6 | Drive Wheel Bolt Torque 50-25-8 Rear Wheel Bolt Torque 50-25-8 Jacking Locations 50-25-9 Remove and Install Rear Wheel Weights . .. 50-25-10 Group 30—HILLMASTER I HILLMASTER Il Rocker Assembly—RH Side... ; 50-90-2 | HILLMASTER II Rocker Assembly—LH Side. ... 50-30-4 | | i | | ‘TM4697 (01NOVO1) 50-2 WTS and CWS Combines Repair PNe2L Group 05 | Transmission and Differential | Other Material umber | T¥6304 (U.S) Ty16021 (U.S.) Tv6252 (US.) AR41870 (U.S.) TY16285 (US) 743512 (U.S.) | Tvea41 (U.S) | TY15130 (US.) Name Flexible Sealant Form-in-Place Gasket 80W90 GLS GEAR LUBE Corrosion Inhibitor Clean and Cure Primer ‘Thread Lock and Sealer (medium strength) Multi-Purpose, SD Polyurea Grease Form-in-Place Gasket Use To seal shifter rail cap. To seal front cover to transmission To coat rotor and stator of | transmission lube pump during assembly and fil transmission. | To protect components in storage. To prime seal shims on lube pump before applying flexible sealant, | To coat threads of cap screws | attaching transmission lube pump, | differential ring gear, differential | cradle, and transmission pinion shaft | carrier. Especially effective in rolling contact applications. To seal hydrostatic motor mount. TMa697 (01NOVOT) 50-05-1 WTS and CWS Combines Repair pneet?Transmission and Differential : = | Specifications } tom Measurement Spectication | Transmission Capacity 96L | 2 (10 at) | | shiter Cam End Play 0.000—0.254 mm | (0.000-0.010 in.) | | Transmission Covero-Housing Cap Torque 73 Nem | | Serews (65 Ib-t) | | Transmission Lube Pump Pressure 0.103 kPa, (1.0 bar) (145 psi) ] Transmission Lube Pump-to-Housing Torque 73 Nem | Cap Screws (65 lb-ft | Input Shaft Oritice Torque 17. Nem (12 Ibett | Pinion Shatt Orifice Torque 17 Nem | | (12 ttt | | Ring Gearo-Differential Cap Screws Torque 180 Nem (97 tb-tt | Differential Preload 0.076—0.254 mm | | {0.003—0.010 in.) | | Differential Cradles-to-Housing Cap Torque 320 Nem | } Screws (285 Ib-t) | Pinion Shatt Bearing Cartier Cap Torque 2.2.Nem | Screws (For determining shim pack) (20 tb-in.) | | Pinion Shatt Preload 0.127 mm (0.008 in.) . Pinion Shaft Bearing Cartier Cap Torque 73 Nem Screws (65 lett Hycrostatic Motor Torque 320 Nem | Mount-to-Transmission Cap Screws {235 tb | | | i I . conn na cuore tessa | ‘TM4697 (OiNOVO) 50-05-2 WTS and CWS Combines Repair PNa2esTransmission and Differential | L | | tem ‘Measurement ‘Specification | (0.0005—0.008 in.) | | | ‘Transmission Mounting Cap Screws Torque 320 Nem. | (236 lb-t) | Gearshift Linkage Distance 237 mm | (9.3 in.) | Transmission Weight 306 kg \ (675 ib) | | | Remove and Repair Shifter Forks and Shifter a | Cam NOTE: Shifter fork and/or shifter cam can be replaced without removing transmission. | 4. Drain transmission oil. Remove front cover. | Speciation | Tensmison—Canasty got | | 2. Remove dowel pin (A) | A-Bowel in M4697 (O1NOVOT) 50-05-3 WTS and GWS Combines Repair pneze9l Transmission and Differential | 9: Remove rail (A) and shifter forks (B) and (C). | | A CAUTION: shitter cam compresses a heavy spring. Use caution when removing shifter cam. 4, Inspect shifter cam to be certain grooves are free of burrs and there are no flat spots. Inspect spring pins in | shifter cam. Replace any that are excessively wom or burred. Also inspect mating shifting surfaces on shifter rail There are no wear tolerances for any of the shitter forks or rollers (D). Replace these pars if they appear ae damaged or worn ‘Shiter Fork | shitter Fork 5. When replacing a roller (D) or pin, press pin flush with D—Roller (2 used) = roller. Roller must be able to tum freely on pin. The usual cause for a roller pin to break is clash shitting 6. Inspect all shift collars in the transmission for wear. They can cause the transmission to "jump" out of gear damaging shit forks. incorrectly adjusted shift linkage | can cause excessive wear to shift collars. | TMa697 (01NOVO1) 50-05-4 WTS and CWS Combines Repair PN=250Install Shifter Forks and Shifter Cam | A-Shitter Fork Pin @ used) B-Roller (2 used) D—Shitter Fork 1. Install shifter forks (A) and (D) on shifter rail (E) and install spring pin. 2. Install dowel pin (F). 3. Install rollers and pins (B) and (C). Roller must turn freely on pin and pin must be flush with top of roller, Transmission and Differential E-Rail cap F—Dowel Pin 4, Check for adequate shifter fork movement. All gears must tum freely when transmission is turned by hand, | | NOTE: Apply 1.4 mm (1/16 in.) bead of flexible sealant fo counterbore of housing when installing cap (G). | | ‘TM4697 (01NOVO1) 50-05-5 ~~ WTS and CWS Combines Repair PnezstF—cam G—O-Ring Washer Spring Pin E—Spring Pin 2 used) Transmission and Differential L-Plunger Solenoid N—Cap Serew (2 used) (O—Ball Switch Spacer (o-Serew | 5, instal detont ball (0), Ball must rest against spring | Install arm) with washer (Hand O-ang (6). | insta spring pin), | 6. If shitter cam (F) was removed, adjust cam and arm to specified end play to obtain proper adjustment of | cam. Measure between inside edge of cam and 7. Apply a continuous 1.5 mm (1/16 in.) wide bead of form-in-place gasket to transmission housing. Install | _ cover (B) and tighten cap screws (A) to | specification, | Specification ‘Transmission Covero-Housing bess on cover to eheck end play cap Seno tore Bie | | Spectcation {0.000-0.010 in.) | : ‘TM4697 (01NOVO1) 50-05-6 WTS and CWS Combines Repair PNaaseTransmission and Differential | a. Fill transmission with T¥6252 80W90 GLS Gear Lube oil or approved alternate. (See FUELS AND LUBRICANTS in Section 10, Group 25.) Level must be within 13 mm (122 in.) from bottom of fil hole. Specification 96 oan “Transmission Capacity NOTE: If transmission is placed in rebuilt service parts | storage, add 0.006 L (2 02) of corrosion | inhibitor. | Lounenay omnes) —so-uuor8s Remove and Install Transmission Lube Pump NOTE: Use 100 psi ( 690 kPa) gauge to test lube pump | pressure. See procedure in diagnostic and test ‘manual, If pump is not delivering specified oil pressure, it ‘must be repaired. Pump can be removed without removing transmission, ‘Specification ‘Tranamission Lube Pump— Pressure 0.103 kPa (1.0 ban) (145 psi This style lube pump consists of the internal pump parts separate from the bearing cup and sleeve. 1, Slide oil tube (A) up and out of port in strainer and insert a 1/2 in. plug into port. This will prevent | excessive loss of cil, 2, Remove cap screws (B) securing pump housing (C) to transmission. .. Carefully pull pump housing (C) away from assembly to catch pump drive pin which, in most cases, will fall | from drive shaft, Be careful not to disturb shim pack. 4, Remove oil tubes from pump housing and lay complete assembly aside, Remove rotor and stator assembly. Save drive pin ‘TM4697 (01NOVOT) 50-05-7 Transmission Lube Pump oil Tu | B-Cap Screws (3 used) | (C—Pump Housing | WTS and CWS Combines Repair PNA253L Transmission and Differential 5. Install new parts (B), (K), (J) and (M) to ensure satisfactory oil pressure. Be certain grooves in the new housing (B) for oil tubes are clean before installing new O-rings (M), 6. Clean paint from ends of oil tubes, approximately 52 mm (2 in.), and blow all paint scales from inside of tubes. Install oil tubes in pump housing, 7. Press bearing cup (G) into sleeve (F} and install over bearing cone on input shaft 8. If possible, rotate transmission shafts so that hole in, input shaft is horizontal and insert pump drive pin. If shafts cannot be rotated, use grease to hold pin in place. 9. Assemble bushing (E) and washer (I) on port plate (J) and install on input shatt in that order. 10. Coat rotor and stator (K) with 80W90 GL5 Gear Lube ail. Carefully place rotor and stator assembly into ‘eccentric bore and over drive pin. 11. Position radial stop on port plate (J) to mate with slot in new housing (B) at approximately 5 o'clock position. 12, Determine proper shim pack. (See Assemble Transmission in this group.) After veriying proper bearing setting, install shim pack. Clean surfaces and prime with TY16285 Primer. Apply 1.5 mm (0.06 in.) bead of flexible sealant to housing comer to seal shims 13. Coat threads of attaching bolts with T43512 Thread Lock and Sealer (medium strength). Tighten bolts to specification Specification ‘Tranemission Lube PumptorHousing Cap Serews— Torque 73.Nen (55 ib) 14. Force cil tubes into respective ports. Make certain the fends of the tubes are past O-ring seals and are against bottom of port ‘A-Screw (3 used) B—Housing ‘Shim D—O-Ring E—Bushing Sleeve G—Bearing cup H—Bearing Cone Washer Plate k—Rotor Dowel Pin M—O-Ring (4 used) Continund on not peas ‘TM4697 (01NOVO1) 50-05-8 WTS and CWS Combines Repair PNazsa| Transmission and Differential | { 415. Secure oil tube with clamp and attach lead on | | sending unit. | Remove and Install Suction Screen 4. Push tube (E) into lube pump housing (0). 2. Remove cap screw (A), fitting (B) and screen (C). 3, Clean screen in solvent. 4, Install screen (C), fitting (B) and cap screw (A). 5. Pull tube (E) down into fitting (B). ‘A~Cap Screw B-Fitting cSereen D—Lube Pump Housing | Oil Tube ' | i j | L AG.ovowsss's ~sa-cauavos-1 | TM4697 (01NOVO1) 50-05-9 WTS and CWS Combines Repair PNa255,Transmission and Differential Remove Transmission A CAUTION: Approximate weight of transmission is 306 kg (675 Ib). Specitication Transmission—Weight. 206 kg 1. Remove header from combine. 2. Fully raise feeder house and lower safety stop. | | 3. Block front drive tires. ‘ACN (6 used) | Shield 4, Tur off engine. | 5, Release parking brake, 6. Place transmission in “NEUTRAL: 7. Remove nuts (A). Remove hydrostatic motor without disconnecting lines and place on a suitable stand, | 8. Remove shield (8). 9. Disconnect solenoid wire connectors (A) and connector @). 10. Disconnect and remove shift cable (C) from transmission, | pwite connector uses) g ‘B—Connector ie esi cole k | — } e | — Continued on rst a0 Twabo7 (INOVOH : 50-05-10 WIS and CWS Combines Fepai PNe256l Transmission and Ditferential | 11, Disconnect service brake lines (A). | 12. Disconnect ground speed sensor connector (B). ‘A—Brake Lines (2 used) B-Connector 13, Disconnect both axles’ a, Remove snap rings (A). b. Slide sleeves (B) toward wheel, ©. Remove pins (C) and slide couplings (D) toward wheel. 14, Remove snap rings (A). Slide sleeves (B) toward wheel. Remove pins (C) and slide couplings (D) toward wheel A-Snap Ring (2 used) | B—Sieove @ used) | Pin used) | ‘D—Coupling (2 used) 15. Remove nuts (A) from mechanical park brake balancer (B) cables. 46. Remove park brake cables from balancer (B) under cab, | Aut (2 used) | BBalancer | ‘TM4697 (01NOVO1) 50-05-11 WTS and CWS Combines Repair PNa257Transmission and Differential | | 17. Place a jack under the transmission, 18. Remove two lower attaching nuts (A). Raise transmission slightly and remove two upper nuts, IMPORTANT: Be careful not to bend brake lines while removing transmission. 19, Remove transmission ANut (4 used) Tw4697 (01NOVOT) = 50-05-12 WTS and CWS Combines Repair PN=258Transmission and Differential | M4697 (O1NOVOI) 50-05-13 WTS and CWS Combines Repair PNa2s9| Transmission Components T4697 (01NOVOt) Transmission and Differential as.ovosr est ve ssuuoev2 WTS and CWS Combines Repair PN=260Transmission and Differential 4—-Housing 2—Washer 3—Snap Rng (4 us ‘4Bearing s—cup 6—O-Ring (2 used) 7-Shim (as required) Pinion Carrier 9—Cap Screw 10—O-Ring (8 used) +1011 Tube 12-Cap 19-Plug 14—Cap Screw (3 used) 15—Gear 16—Plate 17 Washer 18-Snap Ring 19-cup 20—Bearing pinion shaft. at—cap 41—Gear 22-Gear ‘42—Shift Collar (2 used) 23-Screen 42—Snop Ring 24—Fiting 44—Bearing 45—Cup ‘46—0-Ring 47—Snap Ring 26—O-Ring 48—Cap 29—Spring Pin 49—Cup ‘30—Shift Arm 50—Bearing 31—Washer 51—Pinlon ‘32—Shift Cam 52—Gear 33—Spring ‘34—Detent Ball 35—Pin (2 used) 36—Pin 56—Shit Rail 37 Input Shatt 57—Hydrostatic Motor Mount 38—Key (2 used) 58-Stud (4 used) ‘29—Orifice (2 used) '59—Cap Screw (4 used) 40—Gear Transmission Recondition ‘Transmission recondition includes the input shatt and the Refer to shifter forks and shifter cam for removal Refer to transmission lube pump for its removal, Remove oil screen, | Remove the remaining bearing cartier on the side of | transmission. TM4697 (O1NOVO1) ~ 50-05-15 60—Breather 61—Shift Fork 62—Roller (2 used) 69—Pin (2 used) 4—shitter 65—Yoke {66—Cap Screw (3 used) 667—Cap Screw (2 used) 668—Cap Screw (2 used) 68—Plunger 70—Solenoid 7i—Cap Screw (2 used) 72-Serew 73—Spacer 74—Ball Switch 75—Piston 76—Cover 77—Washer (2 used) 78—Nut (2 used) WTS and CWS Combines Repair PINs 1Transmission and Differential Disassemble and Repair Transmission Inout Shatt Assemoly 10-Plug 19--Breather 28-Gear 11—Tube 20-Screw (4 used) 29—Key 12-Shim Pack 21—Stud (4 used) ‘30—Dowel Pin 13-0-Ring 22 Hydrostatic Motor Mount 31—Orifice 14Tube 23—Bearing Cup ‘32—Input Shaft || 6 Beering Cone 15—Cap Screw 24—Bearing Cone 33—Input Shaft Kit O-Ring (6 used) 16-Fitting 25—Snap Ring 34—Coupling | 8—0ll Pump 17—O-Ring (2 used) 26—Shitt Collar 35—Snap Ring (2 used) 9Serew (3 used) 18-Sereen 27—Gear '36—-Flange Nut (4 used) ‘TM4697 (01NOVO1) 50-05-16 WTS and CWS Combines Repair PN=262Transmission and Ditferential | 1, Remove shifter forks. (See procedure in this group.) | 2. Remove lube pump, (See procedure inthis group) | | 3, Remove hydrostatic motor. (See procedure in Group 15) 4, Remove input shaft assembly. | 5, Press bearings off both ends of shat. 6. Remove snap ring from shift collar end of shaft 7. Press gear (A) off shaft and slide gear (C) and shift collar (B) off shatt 8. Check orifice (31) and oil passage through input shaft for restriction. Clean thoroughly. Tighten orifice to specification. Specification Input Shalt Otee—Torque 17 Nm asa | (rete) : 8 | 9. Replace parts as necessary. Q Gear Shit Collar Gear | | | ontnd onc ps scouonasay csesmuaveare | M4697 (O1NOVOT) 50-05-17 WTS and CWS Combines Repair PN=263Transmission and Differential i 3 = 2 5 ‘AcLube Pump Drive Pin D-Gear Fear H-Bearing Cone Bearing Cone Shit Collar Snap Ring Key CHinput shat 10, Assemble input shaft parts M4697 (01NOVOT) 7 50-05-18 WTS and CWS Combines Repair PNazesTransmission and Differential Pio Sat Assembly | ‘A-Pnion Cacier washer N-key Pinion Shaft Kit | Bocap serew (used) Gear monte SBenring Cone | | Shim Pack Geer PPnion Satt (Heavy Duty T—Besring Cup | booing ieshit Collr Transmission) U=eap E—Booring Con (econ a—Pinion shat (Standard V—O-Ring | FBearing Gone ticeer Duy Tanemission)— W—Snap ng (G—Snap Ring (4 used) 11. Remove right-hand diferent beeing carer to allow | °°" Femoval of the pinion shalt i | , B 12. Press bearings off both ends of shat. é NOTE: Move gear end of differential toward rear of | transmission. \ ey, | 18, Remove snap rings (G) to remove gears. seteomesi | | ‘TM4697 (01NOVO1) 50-05-19 WTS and CWS Combines Repair PNA265Transmission and Differential 14, Press gear off shaft, | 15. Check onfice (0) and oil passage through pinion shaft (®) oF (Q) for restriction. Clean thoroughly, Tighten orifice to specification. Sptcieton 3 | cn Sat corer rn ee ween ge 16. Replace parts as necessary. | 17. Assemble parts on shaft ‘Stand Duty Transmission Shown | Centon on net page ac.ovoets cra a-cavaveo-ris ‘TM4697 (01NOVO1) 50-05-20 WTS and CWS Combines Repair PN=266Transmission and Differential | 8 | 3 | 7 | | Ea | Diteretat | ‘A—Seal (2 used) H—Bearing Cone (2 used) ‘M—Housing ‘S—Snap Ring (2 used) | ScsnepAing used) cup eed) noshim T Noes Boring (62 used) CoRoler Bewng (2 used) Cap Sram (4 used) O—Trvust Washer (2 ves) | Sobre shot used)” King Goa Heavy Duly Ptvust Washer (2 sed) Ecap Seren (12 used) Transmission) OoPion (2 wed) | | Fore sea) L-Ring Gon Sander Duty ROTrue Washer @ used) Xing Pn | G—O-Ring (2 used) Transmission) | Gaon Uae ine os ee 18. Remove drive shats and remove cradles components. IMPORTANT: Do not damage plastic or aluminum shims between transmission case and cradles. : continued on nest pa sc ounsesssio -sncsnveo-ans | ‘TM4697 (01NOVO1) 50-05-21 WTS and CWS Combines Repair PNa267Transmission and Differential | 19. Remove snap ring (B) to remove bearing (A), B-Snap Ring 20. Remove cap screws (A) to remove ring gear (B). | ‘A—Cap Screw (14 used) Bing Gear Heavy Duty Diferential Shown | 21. Remove spring pin, z 2 | 3 3 | i | = Conte co nex pee naouowssers secwavnnne | M4697 (O1NOVOT) 50-05-22 WTS and CWS Gombines Repair PN=268Transmission and Differential 22, Remove snap rings. 28. Remove shaft, pinion gears and bevel gears. | 24, Replace parts as necessary. 25. Pack all bearings with Multi-Purpose SD Polyurea Grease. Apply a light coat of grease to housing before pressing in bearing cups 26. Coat thrust surfaces and bores of bevel gears and pinion gears with oil. 27. Install bevel gears, pinion gears, thrust washers and differential pins. Install snap rings. All gears must rotate freely. 28. Install ring gear (B). Apply thread lock and sealer (medium strength) to cap screw threads. Install cap screws (A) and tighten to specification. Specitication Fing Gear-to-Diferental Cap Screws—Torque 130 Nem @7 bt) ‘A—Cap Serew (14 used) B-Ring Gear | ‘ a Heavy Duty Diferental Shown | ‘TM4697 (01NOVO1) 50-05-23 WTS and CWS Combines Repair PN=26eTransnission and Diente | 29. Install nner snap ring and press bearing cone (A) into | cradle. Install outer snap ring (B) and install shaft | seal. Press flush with housing. Apply Multipurpose SD. Polyurea Grease to seal lip. | A-Bearing BSnap Ring Assemble Transmission A CAUTION: Use a lifting device of adequate | capacity for heavy components, | 1. Install differential (A) in transmission housing. Use a E wood block (B) to position differential a A—Differential 5 | | B-Bheet 3 2 Heavy Duty Transmsen Shown | | | | | a extol oc pe ‘TM4697 (01NOVO1) = 50-05-24 "WTS and CWS Combines Repair PNea70Transmission and Differential NOTE: Move the gear end of differential toward rear of transmission to allow installation of pinion | assembly. 2. Install pinion assembly. Be sure pinion shaft gear (B) meshes with differential gear (A). | 3. Ifold shims (behind cradle) were not damaged, they | may be used. Otherwise, assemble a new pack. Start with several shims to ensure end play. cS Ge 4, Install cradles. mS: Heavy Duty Transmission Shown 5. Check differential preload. Add or remove shims as op needed. Apply Thread Lock and Sealer (medium Cobras coe strength) to cap screw threads. Tighten to specification | Specification Diferental—Proioad, 0.076—0.254 mm (0.003—0.010 in) Specitication Differential Cradles-to-Housing Cap Serews—Torus. 320 Nem (235 ts) luosamr arene —seenotos 6. Install bearing cup, cap, O-ting and retaining ring (A— D). A-Becring Cup | B—Cap e-o-ning ©@ D—Retaining Ring a OO: | | { | ‘TM4697 (01NOVO1) 50-05-25 WTS and CWS Combines Repair PNeartTransmission and Differential | IMPORTANT: The following procedure must be followed when determining required shim pack for the pinion shaft. This ® | Prevents false end play readings = ‘caused by retaining ring. (G a 7. Install bearing carrier (B). Leave O-ring (D) off at this a v time. a 8 8. Evenly tighten cap screws to specification. ¥ Specification Pinion Shaft Bearing Carrer Cap | Screws (For gotomining shin - pasorctoe 22tm Bearing Carer 20 bin} ‘C—Shim (as required) D—0-Fing - 9. Rotate pinion shatt at least two complete revolutions. Bearing Cup | ‘Again evenly tighten cap screws to specication, | | Specification | Pinion Sha Bearing Cartier Cap Screws (For determining shin | ack}—Torqve 22Nem @0ibin} 10. Measure gap between bearing carrier (B) and housing | al two places exactly 180° apan. Install shim pack (C) equal to average of these two readings. This shim | pack will provide specified preload. Specitication | } Pinion Shat—Pretoad 0.127 mm (0.005 in) 11. Install O-ring on carrier and install shim pack and carrier. | 12, Apply Thread Lock and Sealer (medium strength) to | cap screw threads. Install cap screws and tighten to specification, Specification = | Prion Shat Bearing Carer Cap | Sereus—Terque 73m | (55 tt) | 13, Install input shaft assembly in transmission. | | | L _ _Centinutd on next page -2unsos7. 000 s | ‘TM4697 (01NOVO1) 50-05-26 WTS and CWS Combines Repair PNeor2Transmission and Differential | 14 App ominplc ase ae oot Specification Hysiostatle Motor Mountto-Tranemission Cap Sorens—Torque 20 Kern (235 bt) 15, Install lube pump. (See procedure in this group.) 16, Adjust lube pump shim pack to provide specified axial end play of input shalt assembly. Specitication | | input Shalt Assomby—Axal End Pay, 001-02 mm (0.00050 008 in.) 17. Install hydrostatic motor. (See procedure in Group 18.) Install Transmission CAUTION: Use a lifting device for heavy ‘components. Raise feeder house and lower safety stop. 1, Use jack to position transmission. Install two lower attaching nuts (A) and upper nuts. Tighten to specification. instr ‘come wie eed | (235 tt) | Lube. (See FUELS AND LUBRICANTS in Section 10, Group 25.) Level must be within 13 mm (1/2 in.) from bottom of fil plug, | | TM4697 (01NOVO1) 50-05-27 WTS and CWS Combines RepairTransmission and Differential Il | 3. Connect service brake lines (A). Bleed air from service brake system. (See procedure in Section 60.) 4. Connect ground speed sensor connector (B). | ABrake Lines (2 used) B_Connector | 5. Slide couplers (D) onto shaft and install pins (C). 6. Slide sleeves (B) over couplers (D) and retain with ‘snap rings (A). ‘A~Snap Ring (2 used) J —--B-Sleeve (2 used) C—Pin (2 usea) Coupling (2 used) | 7. Connect wire connectors (A) and connector (B). 8. Connect shift cable (C) to transmission. 9. Adjust gearshift linkage. (See ADJUST GEARSHIFT LINKAGE in this group.) ‘A—Wire Connector (2 used) B—Connector C—Shit Cable ~ WTS and WS Combines Repair Pueera TM4697 (01NOVO1) 50-05-28| Transmission and Differential 40. Install hydrostatic motor and install nuts (A). Tighten to specification Specification Hydrostatic Motorto-Transmission Mount Cap Serews—Torque m5 tem (@5 wt) 411. Install shield (B). | 12, Install park brake cables in balancer (B). | 49. Install nuts (A) on park brake cables. 14. Adjust park brake, (See procedure in Section 60.) | A-nut @ uses) e | a. 3 | | ; | H j i 744697 (01NOVOT) 50-05-29 WTS and CWS Combines Repair Nearsl Transmission and Differential Remove and Install Gearshift Lever and Linkage ‘TM4697 (01NOVO1) 50-05-30 WTS and CWS Combines Repair PNA276Transmission and Ditferential | [ acoob sea Nteoiator 1=clamp | Nut Housing O—Bracket U—Cap Screw — | evap serew Bracket P—Cap Screw v—ciamp | D—shiter Ros KWasher ‘O—Bal Joint wonut ECap Serew LCariage Bot RON X—Cap Seren | M—Cap Screw sat YoLabel | 1, Remove knob (A). 4, Install parts as needed. Install knob (A). 2. Remove parts as needed 5. Adjust gearshift linkage. (See procedure in this group.) 3. Inspect and replace parts as necessary. | | L cuomseneer —pownor22 | ‘TM4697 (01NOVO1) 50-05-31 WTS and CWS Combines Repair pueer?Transmission and Differential | Adjust Gearshift Linkage | | 1. Shift transmission into second gear. Gearshift lever | should be leaning slightly forward, } | 2. From under cab, loosen nut (A). Remove and adjust ball joint (B) to specified dimension (C). Do not adjust clamp (0) Specification Gearshit Likage—Distance, 237 mm (031m) 3. At transmission, remove ball joint (G) from shift arm (E). Shift arm should be straight down, 4, Loosen nut (F) and adjust ball joint (G) until stud on ball joint aligns with hole in shift arm (E). Reinstall ball joint (G) to shit arm (E). 8. Check for specified dimension (H). Do not adjust clamp 0. Specification Gearshit Likage—Distance 237 mm (@3in) AONut BBall Joint ‘C—Dimension D—clame E-Shitt Arm Nut ‘TM4697 (01NOVO1) 50-05-32 WTS and CWS Combines Repair PNaa7aGroup 10 | | Single Reduction Final Drive | Essential or Recommended Tools NOTE: Order tools from the U.S. SERVICEGARD or RECOMMENDED TOOLS, as noted, are suggested to European Microiche Too! Catalogs. perform the job correctly. Some tools may be avaliable from local suppliers oF may be fabricated ESSENTIAL TOOLS liste are required to perform the job correctly and are obtainable onty from ‘SERVICEGARD or European Microfiche Too! | Catalogs | Service Jack . - . B05070ST To remove and install final drives. Ac ovosissent —se.omavo028 | Final Drive Adapter 705874 Use with DO5070ST service jack to remove and install final drives | | | 8 | ¥ : Final Drive Spindle Nut Socket. . pases To remove and install spindle nut. | l Continued on nt as ‘TM4697 (01NOVO1) 50-10-1 WTS and CWS Combines Repair NearSingle Reduction Final Drive Final Drive Repair Kit -. - .J0G690 To repair final drive. Final Drive Repair Kit~Heavy Duty. -JDG1296 Used in conjunction with JOG&90 to repair heavy duty | final drive. Ag ovoets cou eames Service Equipment and Tools | NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Too! Catalog (MTC). Some tools may be available from a local supplier. | 17-172 and 30-Ton Puller Set To remove and install bearings and seals. | condos on ngage ssovosasers spawnvios | ‘TM4697 (01NOVO1) 50-10-2 WTS and CWS Combines Repair PN=200Single Reduction Final Drive | Bushing, Bearing, and Seal Driver Set To remove and install bushings, bearings and seals. Dial indicator To check pinion gear shait preloadiend play. Other Material Number Name Use | TY15130 (US.) Form-in-Place Gasket Seal inner and outer housing. | T6282 (U.S.) @0W90 GL5 GEAR LUBE To service final drives. Tv6304 (U.S.) Flexible Sealant Seal final drive end cap and final a drive pinion cap. Ty6341 (US.) Multipurpose SD Polyurea Grease To pack bearings and lubricate drive shait splines and coupler. AR41870 (U.S.) Corrosion Inhibitor Protect components in storage. Tw4697 (O1NOVOT) 50-10-3 WTS and CWS Combines Repair PNe2etSingle Reduction Final Drive Specifications | tem Front Tire and Wheel Final Drive | Final Drive-to-Axle Cap Screws Top Two Cap Screws Bottom Two Rear Cap Screws Bottom Two Front Cap Screws FE coer Inner Housing-to-Outer Housing Cap Screws Shim Pack Plastic (2 used) Steel (1 used) Steel (1 used) Outer Housing Cap Screws Pinion Gear Shaft Adjustment Bearing Cap Screws | Spindle Bearing Measurement Approximate Weight (without ballast) Weight Torque Torque Torque Torque Torque Thickness Thickness Thickness Torque Preload/Endplay Torque Housing Deflection Specitiation 400 kg (882 Ib) 233 kg (814 Ib) 405 Nem (300 tb-tt 200 Nem + 90° (148 Ib-ft) + (1/4 Tum) 200 Nem + 180° (148 Ibetty + (1/2 Turn) 200 Nem + 90° (10 Ib-tt) + (1/4 Turn) 320 Nem (235 Ib-tt) 0.13 mm (0.008 jin.) 0.25 mm (0.010 in.) 0.50 mm (0.020 in.) 12 Nem (106 Ibn.) 00.1 mm (00.004 in.) preload to | (00.05 mm (00.002 in.) end play 73 Nem (55 lb-ft) 0,30—0.96 mm (0.012—0.014 in.) Spindle Bearing Adjustment Torque 375 Nem | (alternate method) (275 Ib-tt) | ‘TM4697 (01NOVO1) 50-10-4 WTS and CWS Combines Repair PNq282I Single Reduction Final Drive Remove and Install Final Drive | CAUTION: Grain tank must be empty and header removed. 1. Set parking brake and block up wheels. | 2. Loosen whee! bots one tum. Do not remove at this time A CAUTION: Block up front axle before removing wheels. BA CAUTION: Jack must have a minimum rating of 5443 kg (6 ton). 8. Raise combine using jack (A) positioned in jack pocket. Jack pockets are located on either side on combine near the feeder house lift cylinder attachment points. 4, Block up front axle (B) or install JT02043 12-Ton ‘Support stand. 5. Support tire and wheel and remove wheel bolts to remove front tire and wheel. A—sack BFront Axle Speciation | | Front Tie and wneet— | | Approximate Weigh (without | bala 400 kg (e821) | ‘TM4697 (01NOVO1) 50-10-5 WTS and CWS Combines Repair PNa283Single Reduction Final Drive inward, 8. Drain final drive, ‘ASpiral Snap Ring B-Sleeve | oPin D—Coupler 6. Pry out spiral snap ring (A) and slide sleeve (B) 7. Drive out pin (C) and drive coupler (D) inward, Final Orve—Weight ‘TM4697 (01NOVO1) ‘Speeitication BE a 222228 gers tae is 233 kg (514 Ib). 9. Use DO5070ST Service Jack (C) with JTO5874 Final Drive Adapter (B) to remove final drive (A). 283 ko 14 B) 50-10-6 g 5 e = | ee WTS and CWS Combines Repair pnszeaSingle Reduction Final Drive 10. Remove cap screws (A)—(C). 11. If dowel pins do not come out with final drive, remove from axle and install in housing. 12, Remove and repair final drive as necessary. (See DISASSEMBLE AND ASSEMBLE FINAL DRIVE in this group.) 13, Install axle spacers if necessary. See Specifications in this group for bolt torques. ‘A—Cap Screw (2 used) BGap Screw (2 used) (C—Cap Serew (2 used) | 14, Use DO0S070ST Service Jack (C) with JT05874 Final By CAUTION: The approximate weight of final rive is 233 kg (614 Ib). Specification Final Deive—Weight 239 kg 140) Drive Adapter (B) to install final drive (A). M4697 (O1NOVOI) 50-10-7 WTS and CWS Combines Repair PN=285r E ee Single Reduction Final Drive 15. Install six cap screws (A)—(C). 16. Tighten cap screws to specifications, Final Drivesto-Axle Cap Screws--Specification “Top Two Cap Screws—Torgue. 405 Nem (200 te) Botlom Two Rear Cap Serews— Torque 200 Nem + 901 (148 to + (174 Turn) Bottom Two Front Cap Screws— Torque 200 Nem + 180° (148 w-) + (12 Tum) 17. Apply Multipurpose SD Polyurea Grease to drive shaft splines and coupler. ‘A—Cap Screw (2 used) B—Cap Screw (2 used) (C—Cap Screw (2 used) 18. Drive coupler (D) toward final drive and drive in pin {C) flush with coupler. 19. Slide sleeve (B) on and install spiral snap ring (A). 20. Fill inal drive with 8.5 L (9 qt) of 80W90 GL5 Gear Lube. (See FUELS AND LUBRICANTS in Section 10, Group 25.) A CAUTION: The approximate weight of tie and ‘wheel is 400 kg (882 Ib) (without liquid ballast). 21. Install wheel. Tighten bolts to specification ‘A—Spiral Snap Ring B-Sleeve Specitication in Front Whee! Bots—Torque 2001Nen +90 D—Coupler Gia0 sk) + (4 Tamm) : ovoerstenuse -sesmuaosz7 | M4697 (O1NOVO1) 50-10-8 WTS and CWS Combines Repair PNa286Single Reduction Final Drive | Disassemble and Assemble Final Drive | ‘Sing Reduction Fina! Drive t-Axle 9—Fitting (2 used) 17-Bearing Cup 2-Seal 10-Line 18-Bearing Cone ‘3-Seal 11—Dowel Pin (2 used) | 4 Bearing Cone 12-Ring Gear ‘5—Bearing Cup 13 Inner Housing 6—Seal 14Plug Grease Fitting 15—Snap Ring | ower tow 16—Spacer BA CAUTION: The approximate weight of final drive is 233 kg (514 Ib). 1, Stand final drive on axle flange. 25—Pinion Gear | P 30—Cap Screw (4 used) ‘31—Cap Serew (12 used) 22-Seal | Speciation Fal Dive—Weght 201g eu | | — ont enn ie paouomaies -reasaniev | M4697 (01NOVOT) 50-10-9 WTS and GWS Combines Repair‘Single Reduction Final Drive 2. Pry off cap (C). Remove retaining ring (D) and key (B). 8, Remove nut (A) using JDGS65 socket (E) acnut okey cap D-Retaining Ring E-Socket 4, Use adapter JOG690-3 (A) from JDG690 Final Drive Repair Kit on end of shaft to protect shaft when removing inner cover. A—Adapter 50-10-10 "WTS and CWS Combines Repair PN=288 T4697 (01NOVO)l Single Reduction Final Drive | 5, Remove cap screws (C). i \ NOTE: Earlier made JOG690-1 Puller Adapter Plates may | | need to be modified for servicing heavy duty final t drives. Mounting holes will need to be enlarged to x 25 mm (1 in). 6. Attach JDG690-1 Adapter Plate (A) from JDG690 Final Drive Repair Kit to inner cover (B). Attach 17-1/2 and 30 ton puller set to plate, Install lifing chains on cross straps of puller set to lit cover after itis disconnected, 7. Thread puller screw (D) into adapter (E) on axle shaft, | 8. Use puller to remove inner cover. Remove bearing cone and spacer. | 9. Clean gasket material from housings. Run a wire through ventiill plug to be sure it is open. ‘A—J0G690-1 Adapter Plate BHInner Cover (C—Cap Screw (12 used) Puller Screw E—Adapter 10. Inspect bearing cup (A). If replacement is necessary, drive bearing cup from inner housing. ‘A~Bearing Cup TM4697 (01NOVO1) 50-10-11 WTS and CWS Combines Repair pucateSingle Reduction Final Drive I |11, Apply alight coat of Mul-Purpose SD Polyurea | {grease to inner housing bore. 12. Drive bearing cup into bore of inner housing, | 13. Remove pinion gear and bearing cup (A). | 14. Remove seal from pinion shatt bore, ‘A—Bearing Cup i 15. Inspect bearing cup (A). I replacement is necessary, drive bearing cup from pinion shaft bore. 16. Apply a light coat of Mult Purpose SD Polyurea Grease, to pinion shaft bore. Drive in bearing cup. 417. Install seal (A) in pinion shaft bore, flush with housing. A-Seat 3 4 | eel ‘M4697 (01NOVO1) 50-10-12 WTS and CWS Combines Repair pN=200Single Reduction Final Drive 18. Remove bearing cones (B) (using beating cone holding fixture (A) from JDG1296 Final Drive Repair Kit, and a paler from pinion shaft iit is necessary to replace bearings. ‘A—Bearing Cone Holding Fixture ‘8 —Bearing Cones (2 used) 19. 20. Pack bearing cones with Multi-Purpose SD Polyurea Grease (or equivalent) and install bearing cones (A) on pinion shaft using driver from JDG1296 Final Drive Repair Kit Install pinion shaft and bearing cup in inner housing. ‘A—Bearing Cones | 21 22 | 23. TM4697 (01NOVOT) CAUTION: Use a lifting device for heavy components. Lift ring gear (A) off axle. Remove outer housing (J) from axle shaft. Turn housing over and, if necessary, remove bearing cap (H) and shim pack (G). Remove bearing cup and seal from bore of outer housing if replacement is necessary. 50-10-13 ‘A-Ring Gear B-Bearing Cup (c—Bearing Cone: ‘D-Pinion Gear E—Bearing Cone F—Bearing Cup ‘G—Shim Pack (as required) H—Beating Cap cap Screw (4 used) ‘J—Outer Housing kAnner Housing continued oo net page ss.ouoean 29 WTS and CWS Combines Repair PN=291Single Reduction Final Drive 24, Install seal (A) and seal cup (B) in outer housing A-Seal B-Seal Cup | 25. Apply a light coat of Multi-Purpose SD Polyurea Grease to bore of outer housing. Install bearing cup (Ay | 26. The seal should be installed on spindle after bearing. ‘The Vsip of the seal MUST be pointed away from the bearing, Grease to the V-lip. ‘A~Bearing Cup 28. Remove V-ring seal (A), bearing cone (B), and seal (©) from axle using puller from JDG1296 Final Drive | Repair Kit and 17-1/2 and 30 ton puller set NOTE: Long puller legs (D) must be used. | Aev-Ring Seal B-Bearing Cone c-Seal | | (D—Long Puller Leg (2 used) | 5 i 5 § ontiued on nest oage c=. 25001871 TM4697 (01NOVO1) 50-10-14 WTS and CWS Combines Repair PNe292Single Reduction Final Drive 29. Apply Multi-Purpose SD Polyurea Grease to seal lips. Install seal (C) using drivers (A) and (B) from 4JDG1296 Final Drive Repair Kit and 17-1/2 and 90, ton puller set. Metal edge of seal (C) must face toward outer housing when placed over axle. A~Driver B—Driver c—Seat NOTE: Pack all bearing cones with Multi-Purpose SD Polyurea Grease before assembly. 30. Thread puller screw (D) into adapter (C) on axle shaft. Install bearing cone (B) on axle using driver (A) from JDG1296 Final Drive Repair Kit and 17-1/2 and, ‘30 ton puller set. 31. Install V-ring seal next to bearing cone. V-lip must be pointed away from bearing cone. 2. Install outer housing on axle. ‘A—Driver B—Bearing Cone C—Adapter D—Puller Serew 2 i 3 g : TM4697 (01NOVO1) 50-10-15, WTS and CWS Combines Repair PNe2asingle Redicton Fl Orne 33. Install snap ring in ring gear and install ring gear (C) on axle. Install spacer (A) with chamfered or beveled edge toward bearing, 34. Block up ring gear using a 50 x 100 mm (2 x 4 in.) block (8) : 35. Apply a 1.5 mm (0.06 in.) continuous bead of i| formin-place gasket around flange of outer housing. z install inner housing on outer housing. Tighten cap : sorews to specification z | Speeitication Inner Housing to Outer Housing A-Spacer Cap Sereus—Torque 320 Nem 18-50 x 100 mm (2x 4 in) Block (235 i) O-Ring Geer | | 36. Install bearing cone on spindle. 37. Install nut (A). Tighten nut until SNUG with JDG665 socket (E). Do not overiighten bearings. (See ADJUST SPINDLE BEARING in this group.) actot Key cep Retaining Ring E—Socket, | | | | g | || I = es oe | T4697 (O1NOVOT) 50-10-16 WTS and CWS Combines Repair pnazadSingle Reduction Final Drive IMPORTANT: Install plastic shims against each housing cast surface. 8. If old shims have not been damaged, they may be used. If damaged, assemble a new pack (C) as follows: ‘© 0.13 mm (0.005 in.) - Plastic - 2 used | © 0.25 mm (0.010 in.) - Steel - 4 used ‘© 0.50 mm (0.020 in.) - Steel - 1 used 39. Attach bearing cap (B) with shim pack to outer housing (D). Tighten cap sorews (A) to specification, | ‘A—Cap Screw (4 used) oo Specification ing Cap | Bearing Cap-to-Outer Housing (O—Shim (as required) Cap Scrows—Torque (Preload D—Outer Housing Measurement 12.Nem (108 tn) | | Continued on net page ac.cvocozz 128 1900-202 ‘TM4697 (01NOVO1) 50-10-17 WTS and CWS Combines Repair PN-2asSingle Reduction Final Drive 40. Check pinion gear shatt preloadiend play with dial indicator. If not within specifications, remove bearing cap and add or remove shims as needed, After correct setting is achieved, remove cap and apply 1.5 mm (0.06 in.) bead of flexible sealant to lip of cap and install cap. Tighten cap screws to specification, Specification 0.4 mm (@.004 in} Specification Pinion Gear Shaf—End Play. 0.05 mm (0.002 in) Specitication Bearing Cap-o-Outer Housing Cap Screws—Torque 73.Nem 65 Ibs) 41, Pump in Multi-Purpose SD Polyurea Grease at lubrication fiting. Grease must ooze out around seal. NOTE: If final drive is to be placed in service parts storage, add 29.6 mL (1 02.) of AR41870 corrosion inhibitor, ‘TM4697 (01NOVO1) : 50-10-18 WTS and CWS Combines Repair PN=296‘Single Reduction Final Drive | Adjust Spindle Bearing (Preferred Method) 1, Rotate final drive assembly two revolutions to seat lower bearing, 2, Install flat bar across mounting flange. 3, Install dal indicator on bar and with indicator on axle, set dial at zero. 4, Tighten nut (A) until specified housing deflection is observed, ‘Specification Spindle Bearing Adjustment (Prefered Method) —Datlecton 0.30-0.8 mm (0012-0014 in) 5. Advance nut to next locking position and install key and retainer. 6. Apply a bead of flexible sealant to lip of cap and install | cap. Adjust Spindle Bearing (Alternate Method) 1. Rotate final drive assembly two revolutions to seat bearings. 2, Tighten nut (C) to specification. Specification Spindle Bearing Adjustment | iterate Metned)—Torque. 315 Nem (275 1b) 3. Advance nut to next locking position and install key and retainer. | 4, Apply a bead of flexible sealant to lip of cap and install cap. [M4697 (O1NOVOT) 50-10-19 WTS and GWS Combines Repair PNeza7Single Reduction Final Drive ‘TM4697 (01NOVO1) : 50-10-20 WTS and CWS Combines Repair PN=208Group 15 Hydrostatic System Essential or Recommended Tools NOTE: Order tools from the U.S. SERVICEGARD or European Microfiche Too! Catalogs. ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from ‘SERVICEGARD or European Microfiche Tool Catalogs. RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers or may be fabricated. Hydrostatic Transmission Too! Kit. To repair hydrostatic pump and motor. — as aR 7) Seal Remover JD@3s1 | To install rotating seal Snap Ring Pliers . JDGI14 | To remove and install internal snap rings. | soiouatee -e-smavee se TMi4697 (01NOVO1} Service Equipment and Tools NOTE: Order tools according to information given in the U.S, SERVICEGARD Catalog or trom the European Microfiche Too! Catalog (MTC). Some tools may be available from a local supplier. 50-15-1 WTS and CWS Combines Repair PN=299Hydrostatic System le | Portable Filter Caddy 705746 To flush hydraulicihydrostatic system, 3 5] i | Vacuum Pump . . D15032NU To perform service work without draining reservoir. =| 5 3 i : I | Micrometer. ‘flange thickness. To measure piston slipper flange and slipper retainer | SAE Dial Indicator. . D17526¢1 To measure shaft end play. | | Metric Dial indicator. . 1752701 | To measure shaft end play. | vost smn —e-aneIs2 Slide Hammer D01399AA To remove pump trunnions. | - D17511C1 ‘M4697 (O1NOVOT) 50-15-2 WTS and CWS Combines Repair PN=300Spring Scale To check swashplate movement, Depth Micrometer Checking zero angle of swashplate Hydrostatic System Magnetic Base To hold dial indicator. D17525C1 | Lower Clearance Bearing Puller To remove bearing cone from pump shatt Spring Scale | | To check swashplate movement, | 7 i Other Material | score is a rpstered trademark of he a Company. M4697 (01NOVO1) HY-GARD Hydraulic Oil ‘Thread Lock and Sealer (Medium Thread Lock and Sealer (High Electrical Contact Cleaner Use assembly. Number Name TY22000 (U.S.) 749512 (U.S.) ‘Strength) 743513 (U.S.) Strength) 3M #1606 (U.S.) To clean parts. To servicelfiush hydraulic/hydrostatic systems and pre-lube parts during Apply to threads of piston shoulder bolts and holes in swashplate. Apply to holes in swashplate. 50-15-3. WTS and CWS Combines Repair PN=a01