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9540, 9560, 9580 9640, 9660, 9680 WTS and CWS Combines

OPERATORS MANUAL 9540, 9560, 9580, 9640, 9660, 9680 WTS and CWS Combines
OMZ93035 H1 (ENGLISCH)

John Deere Werke Zweibru cken OMZ93035 Issue H1


European Version

ENGLISCH

Introduction
Foreword
INTENDED USE: This combine is designed solely for use in customary agriculture or similar operations. Use in any other way is considered as contrary to the intended use. The manufacture accepts no liability for damage or injury resulting from misuse, and these risks must be borne solely by the user. Compliance with and strict adherence to the conditions of operation, service and repair as specified by the manufacturer also constitute essential elements for the intended use. READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and the safety signs on your machine may also be available in other languages (see your John Deere dealer to order). THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it. MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench. RIGHT-HAND AND LEFT-HAND sides are determined by facing the direction of forward travel. WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Specification or Identification Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the machine. SETTING FUEL DELIVERY BEYOND PUBLISHED factory specifications or otherwise overpowering will result in loss of warranty protection for this machine. BEFORE DELIVERING THIS MACHINE, your dealer performed a predelivery inspection. After operating for the first 20 to 50 hours, schedule an after-sale inspection with your dealer to ensure best performance. THIS COMBINE SHOULD BE OPERATED, serviced and repaired only by persons familiar with all its particular characteristics and acquainted with the relevant safety rules (accident prevention). The accident prevention regulations, all other generally recognized regulations on safety and occupational medicine and the road traffic regulations must be observed at all times. Any arbitrary modifications carried out on this combine will relieve the manufacturer of all liability for any resulting damage or injury.

OUO6075,0000244 1907DEC001/1

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Predelivery Inspection Predelivery Inspection . . . . . . . . . . . . . . . . . . CLIS-1


Identification View Combine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Safety Decal Location Pictorial Safety Signs . . . . . . . . . . . . . . . . . . . . . Operators Manual . . . . . . . . . . . . . . . . . . . . . . . Repair and Maintenance. . . . . . . . . . . . . . . . . . . Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . Front Access Ladder and Platform . . . . . . . . . . . Avoid Motor Vehicle Collisions . . . . . . . . . . . . . . Rear Access Ladder and Service Platform . . . . . Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . Grain Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Header Drive Guard . . . . . . . . . . . . . . . . . . . . . . Feeder House Shield . . . . . . . . . . . . . . . . . . . . . Feeder House Conveyor Chain . . . . . . . . . . . . . Feeder House Safety Stop . . . . . . . . . . . . . . . . . Elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grain Tank Unloading Auger . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . Rotary Screen and Radiator Fan . . . . . . . . . . . . Feeder House Tilt Frame . . . . . . . . . . . . . . . . . . Electrical Power Lines . . . . . . . . . . . . . . . . . . . . Rotary Screen . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Instruments General View of Controls and Instruments . . . . . Switch and Knob Colors . . . . . . . . . . . . . . . . . . . Armrest Control Panel . . . . . . . . . . . . . . . . . . . . Armrest Control Panel (Continued) . . . . . . . . . . . Multi-Function Lever . . . . . . . . . . . . . . . . . . . . . . Corner Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Control Panel . . . . . . . . . . . . . . . . . . . Steering Column. . . . . . . . . . . . . . . . . . . . . . . . .

15-1 15-1 15-1 15-2 15-2 15-2 15-3 15-3 15-3 15-3 15-4 15-4 15-4 15-4 15-5 15-5 15-5 15-6 15-6 15-6 15-6 15-7 15-7 15-7

20-1 20-2 20-3 20-4 20-5 20-6 20-8 20-9

Header Engage / Electro Feeder House Reverser Switch (Yellow) . . . . . . . . . . . . . . . 20-10 Separator Engage Switch (Yellow) . . . . . . . . . . 20-11 Operating Adjustments and Controls . . . . . . . . 20-11 DIAL-A-SPEED Knob (Black) (Optional) . . . . 20-12 Engine Speed Switches (Orange). . . . . . . . . . . 20-14 Response Rate Control For Automatic Functions And Feeder House Reaction Speed Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14 Grain Tank Cover Switch (Black) . . . . . . . . . . . 20-15 Operating Adjustments and Controls Road Transport Disconnect Switch . . . . . . . . 20-16 Ground Drive and Engine Speed Switches Four Wheel Drive Engage. . . . . . . . . . . . . . . 20-17 Operating Adjustments and Controls Manual Reel Speed Switch . . . . . . . . . . . . . . 20-18 Concave Clearance Switch . . . . . . . . . . . . . . 20-18 Cylinder Speed Switch (Black) . . . . . . . . . . . . . 20-19 Cleaning Fan Speed Switch (Black) . . . . . . . . . 20-19 Chopper Vane Adjust Switch (Black) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 Manual Leveling Control Switch (HILLMASTER II) (Optional) . . . . . . . . . . . . . 20-20 Automatic Leveling Control Switch (HILLMASTER II) (Optional) . . . . . . . . . . . . . 20-21 Operating With HILLMASTER II Leveling System (Optional) . . . . . . . . . . . . . . . . . . . . . 20-22 Daily Preparations Before Driving HILLMASTER II Combine (Optional) . . . . . . . 20-23 Operating With Automatic Leveling Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24 Operating With Manual Leveling Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 Multi-Function Lever . . . . . . . . . . . . . . . . . . . . . 20-26 Multi-Function Handle Quick Stop Switch. . . . . . . . . . . . . . . . . . . . . 20-26 Unloading Auger Swing Switch . . . . . . . . . . . 20-27 Multi-Function Lever Unloading Auger Drive Switch. . . . . . . . . . . . 20-28 Activation Buttons (Black). . . . . . . . . . . . . . . . . 20-29 Activation Button Allocation . . . . . . . . . . . . . . . 20-30
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All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT 2001 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual

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Reel Lift/Reel Fore and Aft Switch (Black) . . . . Multi-Function Handle Header Lift Switch. . . . . . . . . . . . . . . . . . . . . Multi-Function Lever Lateral Tilt Switch . . . . . . . . . . . . . . . . . . . . . CLIMATRAKAutomatic Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Mirror Control Switch . . . . . . . . . . . . . . Mirror Heater Switch. . . . . . . . . . . . . . . . . . . . . Windshield Wiper and Windshield Washer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Shifting Feeder House/Header Reverser . . . . .

20-31
20-31
20-32
20-33 20-34 20-34
20-35 20-35 20-36 20-36 20-37 20-38

Warning Devices and Monitors Overhead Warning Display Panel . . . . . . . . . . . . 25-1 Unloading Auger On . . . . . . . . . . . . . . . . . . . . . . 25-2 Low Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2 Overhead Warning Display Park Brake On . . . . . . . . . . . . . . . . . . . . . . . . 25-2 Main Gearcase Drive Filter . . . . . . . . . . . . . . . . . 25-2 Main Gearcase Temp . . . . . . . . . . . . . . . . . . . . . 25-3 Hydraulic Oil Temp. . . . . . . . . . . . . . . . . . . . . . . 25-3 Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3 ENG (Engine) Air Filter. . . . . . . . . . . . . . . . . . . . 25-4 Separator Plugged . . . . . . . . . . . . . . . . . . . . . . . 25-4 Tilt Limit (HILLMASTER II ) . . . . . . . . . . . . . . . . 25-4 Grain Tank Cover Indicator . . . . . . . . . . . . . . . . 25-5 Grain Tank Full. . . . . . . . . . . . . . . . . . . . . . . . . . 25-5 Grain Tank (3/4) Full . . . . . . . . . . . . . . . . . . . . . 25-5 Hydro Charge Pressure . . . . . . . . . . . . . . . . . . . 25-6 Main Gearcase Lube Pressure . . . . . . . . . . . . . . 25-6 Overhead Warning Display ENG (Engine) Temperature . . . . . . . . . . . . . . 25-6 ENG (Engine) Oil Pressure . . . . . . . . . . . . . . . 25-7 High Beam Indicator. . . . . . . . . . . . . . . . . . . . . . 25-7 Straw Chopper (Optional) . . . . . . . . . . . . . . . . . . 25-7 Grain Separator . . . . . . . . . . . . . . . . . . . . . . . . . 25-8 Auger Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . 25-8 Grain Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8 Tailings Elevator. . . . . . . . . . . . . . . . . . . . . . . . . 25-8 Cylinder Speed. . . . . . . . . . . . . . . . . . . . . . . . . . 25-9 Engine Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . 25-9 HEADERTRAK Control Module . . . . . . . . . . . . 25-10 HEADERTRAK Control Display . . . . . . . . . . . . 25-11 Description of HEADERTRAK Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-12 Stubble Height Control . . . . . . . . . . . . . . . . . . . 25-16 Return To Cut . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 Header Width . . . . . . . . . . . . . . . . . . . . . . . . . . 25-20

DIAL-A-SPEED. . . . . . . . . . . . . . . . . . . . . . . . . Lateral Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . Header Ground Pressure . . . . . . . . . . . . . . . . . Reel Position Resume . . . . . . . . . . . . . . . . . . . VISIONTRAKDisplay Module . . . . . . . . . . . . . VISIONTRAK Display Control Switches . . . . . . Calibration Switch. . . . . . . . . . . . . . . . . . . . . . . Up/Down Arrow Switch. . . . . . . . . . . . . . . . . . . Seed Size Switch . . . . . . . . . . . . . . . . . . . . . . . Adjustable Deck Plate Position (Optional). . . . . Tailings Sensor Display . . . . . . . . . . . . . . . . . . Tailings Sensor Display Operational Check . . . VISIONTRAK Performance Monitor . . . . . . . . . Shoe Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . Separator Loss . . . . . . . . . . . . . . . . . . . . . . . . . Total Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary Adjustments on Combine . . . . . . . . VISIONTRAK Performance Monitor (General Information) . . . . . . . . . . . . . . . . . . Operating VISIONTRAK Performance Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Control Switches (VISIONTRAK Monitor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Arrow Switch . . . . . . . . . . . . . . . . . . . . . . Diagnostics Switch . . . . . . . . . . . . . . . . . . . . . . Enter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Area Counter Switch . . . . . . . . . . . . . . . . . . . . Area Counter Operation . . . . . . . . . . . . . . . . . . Triple Display Tachometer . . . . . . . . . . . . . . . . Control Switches . . . . . . . . . . . . . . . . . . . . . . . Engine Speed Switch . . . . . . . . . . . . . . . . . . . . Cylinder Speed Switch . . . . . . . . . . . . . . . . . . . Concave Clearance Switch. . . . . . . . . . . . . . . . Up/Down Arrow Switch (Display Line Select) . . Clock Select Switch . . . . . . . . . . . . . . . . . . . . . Fan Speed Switch . . . . . . . . . . . . . . . . . . . . . . Fixed Speed Feeder House Switch . . . . . . . . . Engine Hours/Separator Hours Switch . . . . . . . Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Temperature Gauge . . . . . . . . . . . . . . Digital Display Lines . . . . . . . . . . . . . . . . . . . . . Tachometer Service Information . . . . . . . . . . . . Diagnostic Icon. . . . . . . . . . . . . . . . . . . . . . . . . Low Shaft Speed Monitor (General Information). . . . . . . . . . . . . . . . . . . . . . . . . . Low Shaft Speed Monitor Troubleshooting . . . .

25-21 25-22 25-24 25-26 25-27 25-27 25-28 25-28 25-28 25-29 25-30 25-31 25-32 25-33 25-33 25-34 25-34
25-35
25-36
25-38 25-39 25-39 25-39 25-39 25-40 25-41 25-42 25-42 25-42 25-43 25-43 25-43 25-43 25-44 25-44 25-45 25-45 25-46 25-47 25-48
25-49 25-50

Calibration Procedures When to Calibrate. . . . . . . . . . . . . . . . . . . . . . . . 30-1 How Diagnostic Address Information is Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
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Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . 30-2 Header Width Calibration . . . . . . . . . . . . . . . . . 30-21 Header Calibration . . . . . . . . . . . . . . . . . . . . . . 30-23 Angle Sensor Calibration . . . . . . . . . . . . . . . . . 30-28 HEADERTRAK Sensor Cable Adjustment . . . . 30-32 Machine Harvesting Threshold Calibration . . . . 30-33 Float Calibration (For Header With Sensors) . . 30-37 Float Calibration (For Header Without Sensors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 Concave Sensor Zero Calibration . . . . . . . . . . . 30-43 Area Counter Enable Calibration . . . . . . . . . . . 30-46 Field Area Counter Clear Calibration . . . . . . . . 30-48 Field Total Area Counter Clear Calibration . . . . 30-49 Deck Plate Sensor Zero Calibration . . . . . . . . . 30-51 Tailings Monitor Calibration . . . . . . . . . . . . . . . 30-55 Chopper Vane Angle Calibration . . . . . . . . . . . 30-56 Clock Calibration . . . . . . . . . . . . . . . . . . . . . . . 30-59 Clear Service (SEU) Indicator. . . . . . . . . . . . . . 30-62
Operators Station Access Ladder to Operators Cab. . . . . . . . . . . . 35-1 Cab Ladder Positions . . . . . . . . . . . . . . . . . . . . . 35-1 Cab Landing Safety Chains . . . . . . . . . . . . . . . . 35-2 Washing Cab Windows, Servicing Head Lights and Wiper. . . . . . . . . . . . . . . . . . . . . . . 35-2 Right-Hand Side Cab Access . . . . . . . . . . . . . . . 35-3 Grain Tank Window/Rear Cab Window Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3 Armrest Storage Box . . . . . . . . . . . . . . . . . . . . . 35-4 Manual Storage . . . . . . . . . . . . . . . . . . . . . . . . . 35-4 GREENSTAR Printer (Optional). . . . . . . . . . . . 35-4 GREENSTAR (Attachment) . . . . . . . . . . . . . . . . 35-5 Cooling Compartment/Recirculation Filter . . . . . . 35-5 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . 35-6 Cab Interior Lights . . . . . . . . . . . . . . . . . . . . . . . 35-6 Auxiliary Power Outlet Strip and SERVICE ADVISOR Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6 Operators Seat Field Office . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-7 Cooling Compartment. . . . . . . . . . . . . . . . . . . . . 35-7 Operators Seat . . . . . . . . . . . . . . . . . . . . . . . . . 35-8 Seat Suspension . . . . . . . . . . . . . . . . . . . . . . 35-9 Adjusting, LH Armrest and Seat Back . . . . . . 35-10 Adjusting RH Armrest and Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-10 Steering Column Wheel Height Adjustment . . . . . . . . . . . . . . . 35-11 Steering Column Tilt Adjustment . . . . . . . . . . . 35-11 Manual Parking Brake . . . . . . . . . . . . . . . . . . . 35-12 Brake Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12 Filling Windshield Washer Reservoir (Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . 35-12

Lights and Signals Light Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 Cab Interior Lights . . . . . . . . . . . . . . . . . . . . . . . 40-1 Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2 Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3 Road Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4 Field Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6 Stubble and Residue Lights . . . . . . . . . . . . . . . . 40-8 Unloading Auger Rear Tail/Stop Light. . . . . . . . . 40-8 Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9 Exit Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9 Unloading Auger Light . . . . . . . . . . . . . . . . . . . 40-10 Work Lights (Optional) . . . . . . . . . . . . . . . . . . . 40-11 Rear Residue Discharge Lights . . . . . . . . . . . . 40-12 Cleaning Shoe Lights . . . . . . . . . . . . . . . . . . . . 40-12 Service Power Receptacles (Optional) . . . . . . . 40-13
Prestarting Checks Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic/Hydraulic Oil Levels . . . . . . . . . . . . . Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System (9540 Combine) . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . After Long Storage Period . . . . . . . . . . . . . . . . . Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricate Combine . . . . . . . . . . . . . . . . . . . . . . . Checks in Operators Cab . . . . . . . . . . . . . . . . . Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45-1 45-2 45-2 45-3 45-3 45-3 45-4 45-4 45-5 45-5 45-6

Operating the Engine Safety Rules for Starting Engine. . . . . . . . . . . . . 50-1 Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . 50-2 Warming up Engine . . . . . . . . . . . . . . . . . . . . . . 50-5 Breaking-In Engine . . . . . . . . . . . . . . . . . . . . . . . 50-6 Break-In Check First 100 Hours . . . . . . . . . . . . . 50-8 Break-In Check After 100 Hours. . . . . . . . . . . . . 50-8 Hot Weather Operation. . . . . . . . . . . . . . . . . . . . 50-9 Cold Weather Operation . . . . . . . . . . . . . . . . . . 50-10 Starting the Engine by Means of a Booster Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . 50-12 Stalling of Engine . . . . . . . . . . . . . . . . . . . . . . . 50-12
Driving and Transporting the Combine Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . Steering and Driving . . . . . . . . . . . . . . . . . . . . . . Manual Parking Brake . . . . . . . . . . . . . . . . . . . . Brake Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . Engaging a Gear . . . . . . . . . . . . . . . . . . . . . . . . Road Safety Switch . . . . . . . . . . . . . . . . . . . . . .

55-1 55-1 55-1 55-2 55-2 55-2

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Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . 55-3 Raising Header. . . . . . . . . . . . . . . . . . . . . . . . . . 55-3 Forward and Reverse Travel . . . . . . . . . . . . . . . 55-3 Reverse Travel Alarm. . . . . . . . . . . . . . . . . . . . . 55-4 Choosing Correct Ground Speed . . . . . . . . . . . . 55-4 Avoid Overheating of Hydrostatic System. . . . . . 55-5 Transport Information . . . . . . . . . . . . . . . . . . . . . 55-5 Transporting Under Own Power . . . . . . . . . . . . . 55-6 Ground Drive and Engine Speed Switches Four Wheel Drive Engage. . . . . . . . . . . . . . . . 55-7 Towing the Combine . . . . . . . . . . . . . . . . . . . . . 55-8 Attaching Machine Safely . . . . . . . . . . . . . . . . . . 55-9 Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10 Transporting Combine on a Trailer . . . . . . . . . . 55-10 Unloading Auger Transport Protection . . . . . . . 55-13
Wheels, Axles and Additional Weights Service Tires Safely . . . . . . . . . . . . . . . . . . . . . . Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Bolt Torque . . . . . . . . . . . . . . . . . . . Drive Wheel Bolt Torque . . . . . . . . . . . . . . . . . . Mounting Tires . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Tires . . . . . . . . . . . . . . . . . . . . . . . . . . Using Liquid Weight . . . . . . . . . . . . . . . . . . . . . . Drive Wheel Starter Stud . . . . . . . . . . . . . . . . . . Wheel Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . Jacking Locations . . . . . . . . . . . . . . . . . . . . . . . .

Combine Cleanout Cleaning Out the Combine . . . . . . . . . . . . . . . . . 80-1


Feeder House Hydraulic Cylinder Safety Stop . . . . . . . . . . . . . . 85-1 Feeder House Side Shields . . . . . . . . . . . . . . . . 85-1 Feeder House Doors . . . . . . . . . . . . . . . . . . . . . 85-2 Cylinder Top Access Door . . . . . . . . . . . . . . . . . 85-2 Bottom Feeder House Door and Feedplate Seal Support . . . . . . . . . . . . . . . . . . . . . . . . . . 85-3 Stone Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-4 Adjusting Fore/Aft Tilt Frame . . . . . . . . . . . . . . . 85-4 Adjusting Feeder Conveyor Chain . . . . . . . . . . . 85-5 Removing Conveyor Chain Links . . . . . . . . . . . . 85-6 Checking Feeder House Conveyor Float . . . . . 85-6 Drum Height Adjustment. . . . . . . . . . . . . . . . . . . 85-7 Changing Feeder Conveyor Speed. . . . . . . . . . . 85-7 Adjusting Feeder Conveyor Drive Chain . . . . . . . 85-8 Slip Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-9 Feeder House Top Shaft Stripper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 85-10 Feeder House Top Shaft Sprockets . . . . . . . . . 85-10 Adjusting Fixed Speed Feeder House Belt . . . . 85-11 HEADERTRAK Tilt Indicator. . . . . . . . . . . . . . . 85-11 Removing Header from Feeder House . . . . . . . 85-12
Separator Left-Hand Drives . . . . . . . . . . . . . . . . . . . . . . . . 90-1 Right-Hand Drives . . . . . . . . . . . . . . . . . . . . . . . 90-3 Dual-Range POSI-TORQ Cylinder Drives. . . . . . 90-4 Single-Range Cylinder Drive. . . . . . . . . . . . . . . . 90-5 Dual Range Cylinder Drive Shear Bolts . . . . . . . 90-5 High-Range Direct Drive (480-980 RPM) . . . . . . 90-6 Low Range (Reduced-Drive) (240-480 RPM) . . . 90-6 Unplugging Cylinder with Breaker Bar . . . . . . . . 90-7 Power Unplugging of Cylinder . . . . . . . . . . . . . . 90-8 Setting Cylinder Access Door to Cylinder . . . . . . 90-9 Cylinder Vibration . . . . . . . . . . . . . . . . . . . . . . . . 90-9 Rear Concave Inserts (Corn Combines) . . . . . . 90-10 Front Concave Closure Plates (Attachment) . . . 90-11 Rear Concave Closure Plates (Attachment) . . . 90-11 Second Concave Curtain (Attachment). . . . . . . 90-12 Power Separator . . . . . . . . . . . . . . . . . . . . . . . 90-12 Straw Walkers/Power Separator Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-12 75 Percent Beater Speed (Optional) . . . . . . . . . 90-13 Separator Curtains . . . . . . . . . . . . . . . . . . . . . . 90-13 Straw Walker Extension Pans . . . . . . . . . . . . . 90-13 Straw Walker Sunflower Flaps . . . . . . . . . . . . . 90-14 Slow Speed Cleaning Fan Drive (Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . 90-14
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60-1 60-1 60-2 60-2 60-3 60-4 60-4 60-4 60-5 60-6

Harvesting Hints Choice of Harvesting Time . . . . . . . . . . . . . . . . . 65-1 Harvesting Tips . . . . . . . . . . . . . . . . . . . . . . . . . 65-1


Automatic Combine Adjust System Automatic Combine Adjust System. . . . . . . . . . . 70-1 Crops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2 Automatic Combine Adjust Display Settings . . . . 70-3 Adjusting Predefined Settings. . . . . . . . . . . . . . . 70-4 Factory Crop 2 (WHEAT 2) and Personal CROP1 CROP5 Setting Changes (Automatic Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-5 Factory Crop 2 (WHEAT 2) and Personal CROP1 CROP5 Setting Changes (Manual Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-6
Crop Settings and Seed Loss Charts Crop Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . Seed Loss Chart (Platforms) . . . . . . . . . . . . . . . Soybean Loss Chart (Row-Crop Heads). . . . . . . Combine and Corn Head Check List . . . . . . . . . Corn Kernel Loss Chart . . . . . . . . . . . . . . . . . . . Power Shutdown Procedure . . . . . . . . . . . . . . . .

75-1 75-4 75-5 75-6 75-7 75-8

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Page

Chaffer Fingers Storage . . . . . . . . . . . . . . . . . . Using Chaffer Fingers. . . . . . . . . . . . . . . . . . . . Precleaner Tool Storage. . . . . . . . . . . . . . . . . . Adjusting Precleaner . . . . . . . . . . . . . . . . . . . . Adjusting Chaffer, Chaffer Extension and Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chaffer Finger Bar Cover (Attachment) . . . . . . Clean Grain Elevator Top Access Cover for Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perforated Screens (Attachment) . . . . . . . . . . . Tailings Elevator Paddles . . . . . . . . . . . . . . . . . Separator Countershaft Strips . . . . . . . . . . . . . Tailings Elevator Slip Clutch . . . . . . . . . . . . . . .

90-14 90-15 90-15 90-15


90-16 90-16
90-17 90-17 90-18 90-18 90-18

Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-6 Transmission, Final Drives, Feeder House Reverser, Dual-Range Cylinder Drive, Primary Countershaft and Loading Auger Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-6 Straw Walker Gearcase . . . . . . . . . . . . . . . . . . 105-7 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-7 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-8 Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . 105-8 Alternative and Synthetic Lubricants. . . . . . . . . 105-8 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-9
Lubrication and Maintenance Service During the Break-In Period (First 100 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . 110-1 Service Intervals. . . . . . . . . . . . . . . . . . . . . . . . 110-1 Lubrication Symbols . . . . . . . . . . . . . . . . . . . . . 110-4 10 Hours or Daily . . . . . . . . . . . . . . . . . . . . . . . 110-5 50 Hours or Weekly . . . . . . . . . . . . . . . . . . . . . 110-8 50 Hours or Weekly (HILLMASTER II Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-12 100 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-13 200 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-14 250 Hours or Yearly . . . . . . . . . . . . . . . . . . . . 110-16 400 Hours or Yearly . . . . . . . . . . . . . . . . . . . . 110-18 800 Hours or Every Two Years . . . . . . . . . . . 110-28 2000 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . 110-29 As Required . . . . . . . . . . . . . . . . . . . . . . . . . . 110-32 Replace Engine Crankshaft Damper 4500 Hours or Five Years . . . . . . . . . . . . . . 110-34 Cleaning Combine . . . . . . . . . . . . . . . . . . . . . 110-34
Shields Left-Hand and Right-Hand Gull Wing Doors . . . Right-Hand Rear Shield . . . . . . . . . . . . . . . . . . Left-Hand Side Separator Shields . . . . . . . . . . Right-Hand Side Separator Side Shield . . . . . . Cleaning Composite Panels . . . . . . . . . . . . . . .
Service - Engine Rear Ladder and Landing. . . . . . . . . . . . . . . . . Engine Compartment Door . . . . . . . . . . . . . . . . Cleaning Engine Compartment . . . . . . . . . . . . . Belt Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Access Panel . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Modify Fuel System . . . . . . . . . . . . . . . Handle Fuel SafelyAvoid Fires . . . . . . . . . . . Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . .

Chopper and Spreader Chopper (General Information) . . . . . . . . . . . . . . Adjusting Chopper Vanes (Manual) . . . . . . . . . . Adjusting Chopper Vanes (Electrical) . . . . . . . . . Adjusting Knives. . . . . . . . . . . . . . . . . . . . . . . . . Chaff Spreader (Optional). . . . . . . . . . . . . . . . . . Chop to Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . Raising and Lowering Chopper Vane Board . . . . Adjusting Spreader Disk Vanes . . . . . . . . . . . . . Removing the Chaff Spreader . . . . . . . . . . . . . .
Grain Tank and Unloading System Grain Tank/Engine Ladder . . . . . . . . . . . . . . . . Grain Tank Drain Holes . . . . . . . . . . . . . . . . . . Operating Grain Tank Covers. . . . . . . . . . . . . . Adjusting Grain Tank 3/4 Indicator . . . . . . . . . . Adjusting Grain Tank Full Indicator. . . . . . . . . . Grain Tank Unloading Auger Covers (Optional) (Standard on Rice Combines). . . . Cross Auger Drive Shear Bolt . . . . . . . . . . . . . Grain Tank Loading Auger Deflector . . . . . . . . Adjusting Unloading Auger Drive Cylinder . . . . Replacing Unloading Auger Drive Cylinder . . . . Vertical Adjustment of Auger Support Stud. . . . Adjust Swing Cylinder Eyebolt . . . . . . . . . . . . . Reduced Speed Unloading System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuels and Lubricants Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storing Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . Liquid Coolant Conditioner . . . . . . . . . . . . . . . . Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . Extended Diesel Engine Oil Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95-1 95-2 95-2 95-3 95-3 95-3 95-4 95-5 95-6

100-1 100-1 100-2 100-3 100-4


100-4 100-5 100-5 100-6 100-6 100-7 100-7
100-8

115-1 115-3 115-4 115-4 115-5

105-1 105-1 105-2 105-3 105-4 105-4 105-5


105-5

120-1 120-1 120-1 120-2 120-2 120-2 120-3 120-3 120-4

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Fuel Tank and Cap. . . . . . . . . . . . . . . . . . . . . . 120-4 Draining Fuel Tank . . . . . . . . . . . . . . . . . . . . . . 120-5 Replacing Fuel Filter (9540 Combine Only) . . . 120-5 Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . 120-6 Water Separator Filter Replacement (9540 Combine Only) . . . . . . . . . . . . . . . . . . . . . . . 120-7 Draining Water Separator . . . . . . . . . . . . . . . . . 120-7 Bleeding Fuel Lines . . . . . . . . . . . . . . . . . . . . . 120-7 Bleeding Engine Fuel Filter (9540 Combine Only) . . . . . . . . . . . . . . . . . . . . . . . 120-8 Bleeding Combine Fuel System . . . . . . . . . . . . 120-9 Drain Cooling System. . . . . . . . . . . . . . . . . . . 120-10 Filling Radiator . . . . . . . . . . . . . . . . . . . . . . . . 120-12 Winterize Cooling System. . . . . . . . . . . . . . . . 120-12 Replacing Engine Fan Belt . . . . . . . . . . . . . . . 120-13 Engine Accessory Drive Belt Routing (6.8 Liter Engine) . . . . . . . . . . . . . . . . . . . . . . . . 120-14 Engine Accessory Drive Belt Routing (8.1 Liter Engine) . . . . . . . . . . . . . . . . . . . . . . . . 120-14 Replace Engine Accessory Drive Belt. . . . . . . 120-15 Rotary Screen Belt Routing . . . . . . . . . . . . . . 120-17 Replacing Rotary Screen Drive Belt . . . . . . . . 120-17 Cleaning Rotary Screen, Oil Cooler, Condenser, Radiator and Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-19 Adjust Rotary Screen Knife Comb . . . . . . . . . 120-20 Removing Air Cleaner Filters . . . . . . . . . . . . . 120-21 Inspecting Element . . . . . . . . . . . . . . . . . . . . . 120-21 Cleaning Element . . . . . . . . . . . . . . . . . . . . . . 120-22 Washing Element . . . . . . . . . . . . . . . . . . . . . . 120-22
Service - Feeder House Hydraulic Cylinder Safety Stop . . . . . . . . . . . . . Replacing Fixed Speed Feeder House Belt . . . Removing Conveyor Chain Links . . . . . . . . . . . Adjusting Feeder Conveyor Drive Chain . . . . . . Adjusting Fixed Speed Feeder House Belt . . . .

Adjusting Straw Walker Gearcase Belt . . . . . . Adjusting Straw Walker Plugging Switch. . . . . Adjusting Cleaning Shoe Auger Gears . . . . . . Replacing Cleaning Shoe Belt . . . . . . . . . . . . Replacing Cleaning Fan Belt . . . . . . . . . . . . . Replacing Clean Grain Elevator Belt . . . . . . . Adjust Clean Grain Elevator Drive Belt . . . . . . Adjusting Clean Grain Elevator Chain. . . . . . . Replacing Tailings Auger and Elevator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Tailings Elevator Belt . . . . . . . . . . . Adjusting Tailings Elevator Drive Chain . . . . . Adjusting Tailings Elevator Paddle Chain . . . . Adjusting Upper Tailings Auger Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130-10 130-11 130-11 130-12 130-13 130-14 130-14 130-15


130-15 130-16 130-16 130-17
130-17

Service - Chopper and Spreader Replacing Knife Sections . . . . . . . . . . . . . . . . . Remove and Replace Straw Chopper Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Replace Counter Knife Bank . . . . Replacing Chopper Belt . . . . . . . . . . . . . . . . . .
Service - Grain Tank and Unloading Adjusting Grain Tank Cross Auger Drive . . . . . Replacing Unloading Auger Drive Belt . . . . . . . Aligning Unloading Auger Drive . . . . . . . . . . . . Adjusting Unloading Auger Drive Cylinder . . . . Replacing Unloading Auger Drive Cylinder . . . . Vertical Adjustment of Auger Support Stud. . . . Adjust Swing Cylinder Eyebolt . . . . . . . . . . . . .
Service - Electrical System Specifications, Electrical System . . . . . . . . . . . Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dangers When Handling Batteries . . . . . . . . . . Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . Checking Electrolyte Level . . . . . . . . . . . . . . . . Checking Specific Gravity. . . . . . . . . . . . . . . . . Battery Switch . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Booster Batteries . . . . . . . . . . . . . . Installing Batteries and Connecting to Correct Poles . . . . . . . . . . . . . . . . . . . . . . . . Welding on Machine . . . . . . . . . . . . . . . . . . . . . Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Distribution Board Relay Identification . . Engine Compartment Relay Panel Fuse Identification . . . . . . . . . . . . . . . . . . . . . . . . . Engine Compartment Relay Panel Identification . . . . . . . . . . . . . . . . . . . . . . . . .

135-1
135-2 135-3 135-3

140-1 140-1 140-2 140-3 140-4 140-4 140-4

125-1 125-2 125-3 125-3 125-4

Service - Separator Adjusting Cylinder Drive Gap . . . . . . . . . . . . . . 130-1 Aligning Cylinder Drive . . . . . . . . . . . . . . . . . . . 130-2 Adjusting Cylinder Belt Idler . . . . . . . . . . . . . . . 130-3 Replacing Cylinder Intermediate Belt . . . . . . . . 130-4 Replacing Cylinder Belt . . . . . . . . . . . . . . . . . . 130-5 Second Concave Adjustment . . . . . . . . . . . . . . 130-6 Adjusting Beater Belt Idler . . . . . . . . . . . . . . . . 130-6 Replacing Beater Belt. . . . . . . . . . . . . . . . . . . . 130-7 Adjusting Secondary Countershaft Belt. . . . . . . 130-7 Replacing Secondary Countershaft Belt . . . . . . 130-8 Replacing Power Separator Belt. . . . . . . . . . . . 130-9 Adjusting Feeder House Drive/Reel Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 130-9 Replacing Feeder House/Reel Pump Belt. . . . 130-10

145-1 145-1 145-1 145-2 145-2 145-3 145-3 145-4


145-4 145-5 145-5 145-6
145-7
145-8

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Safety Rules When Replacing Halogen Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-9 Replacing Bulbs . . . . . . . . . . . . . . . . . . . . . . . . 145-9 Cab Head Light Bulb Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 145-10 Replacing Stubble Light (Optional) Bulb . . . . . 145-11 Replacing Field Light Bulb . . . . . . . . . . . . . . . 145-11 Replacing Side Finder Light Bulb . . . . . . . . . . 145-12 Replacing Grain Tank Light Bulb . . . . . . . . . . 145-12 Replacing Cleaning Shoe Light Bulb . . . . . . . 145-13 Replacing Warning Light Bulb . . . . . . . . . . . . 145-13 Replacing Turn Signal Indicator Light Bulb . . . 145-14 Replacing Dome and Console Light Bulb . . . . 145-14 Replacing Warning Display Panel Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-15 Observe Electrical Precautions . . . . . . . . . . . . 145-15 Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems. . . . . . . 145-16 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-16 Alternator and Voltage Regulator . . . . . . . . . . 145-17 Header Drive Electromagnetic Clutch . . . . . . . 145-17 Antenna Mounting . . . . . . . . . . . . . . . . . . . . . 145-18
Service - Hydraulic System Hydraulic System (General Information) . . . . . . Hydraulic System Cleanliness . . . . . . . . . . . . . Accumulator (General Information) . . . . . . . . . . Valve for Raising/Lowering Header (Proportional Valve) . . . . . . . . . . . . . . . . . . .
Service - Ground Speed Drive Adjusting Gearshift Linkage . . . . . . . . . . . . . . . Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Hydrostatic Oil Cooler . . . . . . . . . . . .
Service - Air Conditioning and Heater Observe Air Conditioning Precautions . . . . . . . CLIMATRAK Air Conditioning System (General Information) . . . . . . . . . . . . . . . . . . Cleaning Fresh Air Filter and Recirculating Filter . . . . . . . . . . . . . . . . . . . . Removing Evaporator Filter . . . . . . . . . . . . . . . Cleaning Cab Roof Inlet Panel . . . . . . . . . . . . . Cleaning Condenser . . . . . . . . . . . . . . . . . . . . . Engine Accessory Drive Belt Routing (6.8 Liter Engine) . . . . . . . . . . . . . . . . . . . . . . . . . Engine Accessory Drive Belt Routing (8.1 Liter Engine) . . . . . . . . . . . . . . . . . . . . . . . . . Removing Compressor Drive Belt. . . . . . . . . . . High Pressure Switch . . . . . . . . . . . . . . . . . . . . Low Pressure Switch . . . . . . . . . . . . . . . . . . . .

Trouble Shooting Feeder House . . . . . . . . . . . . . . . . . . . . . . . . . 165-1 Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165-2 Hydrostatic Ground Drive . . . . . . . . . . . . . . . . . 165-6 4-Wheel Drive (Optional) . . . . . . . . . . . . . . . . . 165-9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165-9 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165-10 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165-11 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165-15 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . 165-16
Storage Preparing Combine for Storage . . . . . . . . . . . . 170-1 Removing Combine from Storage. . . . . . . . . . . 170-2
Specifications Operating Speeds. . . . . . . . . . . . . . . . . . . . . . . 175-1 Whole Body Vibration . . . . . . . . . . . . . . . . . . . . 175-3 Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 175-3 Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . 175-3 Specifications - 9540 Combine Only . . . . . . . . . 175-4 Specifications - 9560, 9580, 9640, 9660, 9680 Combines. . . . . . . . . . . . . . . . . . . . . . . 175-6 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 175-7 Dimension Reference Points . . . . . . . . . . . . . . 175-8 Metric Bolt and Cap Screw Torque Values . . . . 175-9 Unified Inch Bolt and Cap Screw Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175-10 Safety Note Regarding the Subsequent Installation of Electrical and Electronic Appliances and/or Components . . . . . . . . . 175-11 Declaration of Conformity . . . . . . . . . . . . . . . . 175-12
Machine Identification Numbers Type Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . Combine Type Plate . . . . . . . . . . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . . . . . . . Hydrostatic Drive Unit Pump. . . . . . . . . . . . . . . Hydrostatic Drive Unit Motor. . . . . . . . . . . . . . . 2 Speed 4-Wheel Drive Motor . . . . . . . . . . . . . Engine Gearcase . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . . . . . .

150-1 150-2 150-3


150-3

155-1 155-1 155-2 155-2

160-1
160-1
160-2 160-2 160-3 160-3
160-4
160-4 160-5 160-7 160-7

180-1 180-1 180-1 180-2 180-2 180-2 180-3 180-3

vii

101801

PN=7

Contents

viii

101801

PN=8

Predelivery Inspection
Predelivery Inspection
The following checks, adjustments and service jobs were performed prior to delivery of the machine.

Predelivery 1. Is product identification plate on R.H. side of operators platform? 2. Is engine oil level correct? 3. Is engine coolant level correct? 4. Is hydraulic oil level correct? 5. Is lighting system functioning correctly? 6. Is steering system functioning correctly? 7. Are foot brakes functioning correctly?
8. Are gauges, acoustical warning devices and monitors operating correctly? 9. Is parking brake operating correctly? 10. Is transmission operating correctly? 11. Is hydrostatic ground speed drive operating correctly?
12. Is HILLMASTER II leveling system functioning properly?

Inspection 13. Is engine shut-off device working correctly?


14. Reverser operating correctly? 15. Is transmission oil level correct? 16. Is final drive oil level correct? 17. Is fast idle speed of engine correct? 18. Tine separator functioning correctly? 19. All rubber seals in separator area and cleaning unit correct? 20. All belts and chains adjusted correctly?
21. Are all guards, shields etc. installed? 22. Paint and decals smooth and neat? 23. Have all controls and safety rules etc. been explained to the operator?

Signature Dealer/Service Technician:

Date:

OUO6075,0001899 1928JUN011/1

CLIS-1

101801

PN=5

Identification View
Combine

OUO6075,000189A 1928JUN011/1

05-1

101801

PN=6

H68351

UN30MAY01

Safety
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.
UN07DEC88

DX,ALERT 1929SEP981/1

Follow Safety Instructions


Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life. If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

DX,READ 1903MAR931/1

10-1

101801

PN=7

TS201

UN23AUG88

T81389

Safety

Look for Supplemental Information


Occasionally, new or revised information will become available after manuals are printed. To get this up-to-date information into your hands, publication supplements are prepared and supplied to the field in the machine literature package. Supplements can be supplied in the following forms and are usually identified with one of these titles: Direction(s) Sheet Installation Instructions Publications Supplement Before your initial review of the Operators Manual, look through the machine literature package to see if any supplemental information has been provided. If supplied, review this information to determine which operating procedures are impacted or modified by the revised instructions. Pay close attention to CAUTION and IMPORTANT statements as they address your safety, the safety of others, and the safe operation of the machine. Operators Manuals are revised annually, at which time the supplemental information is incorporated directly into the manual, thereby eliminating the supplement

AG,OUO6018,604 1922SEP991/1

Observe Road Traffic Regulations


Always observe local road traffic regulations when using public roads.
OUO6075,0000032 1922JAN011/1

Check Machine Safety


Always check the road and general operating safety of the machine before using.
FX,READY 1928FEB911/1

10-2

101801

PN=8

Safety

Fire Extinguisher
A 6 kg (15 lb.) general purpose fire extinguisher meeting local legal requirements must be installed on the operators station ladder. Maintain fire extinguisher to keep it in operating condition. Keep the engine clean and free of dust, chaff and straw to prevent the possibility of fire.

OUO6075,0001764 1930MAY011/1

Prevent Machine Runaway or Unexpected Movement


Avoid injury or death from unexpected movement of machine or components. Do not start engine by shorting across starter or solenoid terminals. Machine or components may move if the normal circuitry is bypassed.
UN08JUL99

H58737

HX,AG,SF6788 1908JUL991/1

10-3

101801

PN=9

H47152

UN20DEC95

Safety

Driving the Combine


Operate machine only when all guards are correctly installed.
UN16JUN95

Before moving away, always check immediate vicinity of machine (e.g. for children). Ensure adequate visibility. Use the horn as a warning immediately before moving away. Always adapt ground speed to road or field conditions. Avoid making sharp turns when driving up or down slopes or when driving across a slope. Be especially careful when turning on slopes with full grain tank. Attach harvesting units and other implements to combine with extreme care. When making turns, always take into consideration the width of the attachment and the fact that the rear end of the combine swings out. Attachments and ground conditions affect the driving characteristics of the combine. Reduce ground speed when driving on slopes or over uneven ground and before making sharp turns. Before descending a steep hill, shift to a lower gear. Avoid holes, ditches and obstructions which may cause the combine to tip, particularly on hillsides.

ZX,DRIVEXZCO 1927JAN921/1

Road Safety Switch


IMPORTANT: Before driving combine on public roads, make sure that road safety switch is in road position (A). Also move harvesting unit and unloading auger to transport position and close grain tank covers. This ensures that all hydraulic functions with exception of the steering system are not working.

OUO6075,00015A8 1927MAR011/1

10-4

H52044
101801

UN31MAR99

PN=10

ZX002461

Safety

Emergency Exit
Pull tab (A) to begin removal of rubber rope (B). Continue to pull until rope is removed from around window. The window can now be pushed out and allowed to fall free. See your John Deere dealer for window replacement.

AG,OUZXMAY,69 1911OCT991/1

Use Safety Lights and Devices


Prevent collisions between other road users, slow moving tractors with attachments or towed equipment, and self-propelled machines on public roads. Frequently check for traffic from the rear, especially in turns, and use turn signal lights. Use headlights, flashing warning lights, and turn signals day and night. Follow local regulations for equipment lighting and marking. Keep lighting and marking visible, clean, and in good working order. Replace or repair lighting and marking that has been damaged or lost. An implement safety lighting kit is available from your John Deere dealer.

DX,FLASH 1907JUL991/1

Keep Riders and Children Off Machine


Only allow the operator on the machine. Keep riders off the machine except for periods of training or short periods of observation.
UN23AUG88

Riders are subject to injury such as being thrown off the machine. Riders also obstruct the operators view resulting in the machine being operated in an unsafe manner. Children should never be allowed on the machine or in the combine cab when the engine is running. The instructional seat should only be used for instruction or short periods of machine observation, and not for the accommodation of children.

AG,OUO6075,255 1901AUG001/1

10-5

101801

PN=11

TS253

TS951

UN12APR90

ZX018636

UN12NOV99

Safety

Ballasting for Safe Ground Contact


Operating, steering and braking performance of combine can be considerably affected by heavy front end attachments which alter the center of gravity of the combine. To maintain the necessary ground contact, ballast the combine at the rear end as necessary. Observe the maximum permissible axle loads and total weights.
UN10FEB99

HX,AG,SF6782 1905FEB991/1

Radio Aerial
If radio aerial is not secured in its transport position before driving on public roads, it may come into contact with low-hanging electrical cables. This would result in the operator suffering a severe electrical shock. To avoid electrical shock, no portion of the machine should be higher than 4 m. Before transporting machine, bend aerial or remove it.

ZX,ANTENNAXZCO 1927JAN921/1

10-6

101801

PN=12

ZX002464

UN16JUN95

H51907

Safety

Parking and Leaving the Combine


Lower harvesting unit to the ground. Before leaving the combine, disengage harvesting unit and separator. Shut off engine and move gear shift lever to neutral. Apply parking brake, remove key and lock the operators cab. Position chock blocks.

NOTE: Use only chock blocks provided with the machine.


Never leave combine unattended as long as engine is running. Never leave the operators cab when driving.

OUO6075,00014F3 1921FEB011/1

Work In Ventilated Area


Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area
UN23AUG88

DX,AIR 1917FEB991/1

Store Attachments Safely


Stored attachments such as dual wheels, cage wheels, and loaders can fall and cause serious injury or death. Securely store attachments and implements to prevent falling. Keep playing children and bystanders away from storage area.

DX,STORE 1903MAR931/1

10-7

101801

PN=13

TS219

UN23AUG88

TS220

TS230

UN24MAY89

Safety

Handle Fuel SafelyAvoid Fires


Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.
UN23AUG88

Always stop engine before refueling machine. Fill fuel tank outdoors. Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.

DX,FIRE1 1903MAR931/1

Prepare for Emergencies


Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy.
UN23AUG88

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

DX,FIRE2 1903MAR931/1

Wear Protective Clothing


Wear close fitting clothing and safety equipment appropriate to the job. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,WEAR2 1903MAR931/1

10-8

101801

PN=14

TS206

UN23AUG88

TS291

TS202

Safety

Stay Clear of Harvesting Units


Cutterbar, auger, reel and feed rolls cannot be completely shielded due to their function. Stay clear of these moving elements during operation. Always disengage main clutch, shut off engine, set parking and remove key before servicing or unclogging machine.

OUO6075,00014F4 1921FEB011/1

Keep Hands Away From Knives


Never attempt to clear obstructions in front of or on header unless separator is disengaged, engine shut off and key removed.
UN23AUG88

Everyone must be clear of the combine before starting the engine

H01,9000SA,D 1920MAR901/1

Transport Combine With Header Safely


Whenever possible avoid transporting on public roadways with the header attached.
UN07MAY99

If the combine must be transported with the header attached, make sure that the flashing warning lights on the header are operating and the reflective material is clean and visible. The use of a spotter or pilot vehicle is recommended on busy, narrow or hilly roads and when crossing bridges. Drive at a speed that is safe for conditions.

OUO6075,0000034 1922JAN011/1

10-9

101801

PN=15

H51909

TS254

ES118704

UN21MAR95

Safety

Avoid Contact With Moving Parts


Keep hands, feet and clothing away from power driven parts. Never clean, lubricate or adjust machine when it is running.
UN23AUG88

H01,9000SA,E 1915JUN901/1

Cleaning the Grain Tank and Removal of Blockages


Avoid serious injury or death from entanglement in the grain tank cross augers. For functional purposes the cross augers cannot be completely covered. Do not enter the grain tank when the engine is running. Before entering the tank to clean out residual grain always shut off the engine and remove the key. If the grain bridges and fails to flow into the cross augers, shut off the engine, remove the key and open the grain tank cover. From a position on the engine compartment door, use a rod, broom or shovel to break the bridge and restore grain flow.

HX,CTSESA,B1 1906JAN981/1

Stay Clear of Rotating Drive lines


Entanglement in rotating driveline can cause serious injury or death. Keep shields and driveline shields in place at all times. Make sure rotating shields turn freely. Wear close fitting clothing. Stop the engine and be sure PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.

OUO6075,0000340 1908JAN011/1

10-10

101801

PN=16

TS1644

UN22AUG95

TS256

UN23AUG88

TS256

Safety

Guards and Shields


Keep guards and shields in place at all times. Ensure that they are serviceable and installed correctly.
UN21MAR95

Always disengage main clutch, shut off engine, set parking brake and remove key before removing any guards or shields. Keep hands, feet and clothing away from moving parts.

OUO6075,00014F5 1921FEB011/1

Practice Safe Maintenance


Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key and set the parking brake. Allow machine to cool. 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 worn or broken parts. Remove any buildup of grease, oil, or debris. Disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

HX,AG,SF6789 1905MAY991/1

Prevent Machine Damage When Welding


To prevent damage to electronic components be sure to disconnect the single point ground and ECU wiring harness connectors before welding on combine.

HX,AG,SF6790 1920JAN001/1

10-11

101801

PN=17

TS218

UN23AUG88

ES118703

Safety

Service Machines Safely


Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
UN23AUG88

DX,LOOSE 1904JUN901/1

Support Machine Properly


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 lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down. Do not support the machine on cinder blocks, 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 operators manual.

DX,LOWER 1924FEB001/1

Re-torque Wheel Nuts


Retorque wheel nuts as specified in Sections Wheels, Axles and Additional Weights and Lubrication Charts, Periodic Service. Failure to do this could result in a wheel falling off during operation, causing the machine to tip over with serious injury to the operator and extensive damage to the machine.

OUO6075,00019DB 1909AUG011/1

10-12

101801

PN=18

H69604

1909AUG01

TS229

UN23AUG88

TS228

Safety

Remove 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. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you 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 all work in an area that is ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.
UN23AUG88

DX,PAINT 1922OCT991/1

Avoid Heating Near Pressurized Fluid Lines


Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns 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.

DX,TORCH 1903MAR931/1

10-13

101801

PN=19

TS953

UN15MAY90

TS220

Safety

Avoid High-Pressure Fluids


Escaping fluid under pressure can penetrate the skin causing serious injury.
UN23AUG88

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.

DX,FLUID 1903MAR931/1

Protect Against High Pressure Spray


Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body. If an accident occurs, see a doctor immediately. Any high pressure spray 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.
UN18MAR92

DX,SPRAY 1916APR921/1

10-14

101801

PN=20

TS1343

X9811

Safety

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 16C (60F).

DX,SPARKS 1903MAR931/1

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: 1. 2. 3. 4. 5. Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. 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 1530 minutes. Get medical attention immediately. If 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.
UN23AUG88

DX,POISON 1921APR931/1

10-15

101801

PN=21

TS203

TS204

UN23AUG88

Safety

Service Tires Safely


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 hose long enough to allow you to stand to one side 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.

DX,RIM 1924AUG901/1

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, filters, and batteries. Use leakproof 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 Earths atmosphere. Government regulations may require a certified 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, or from your John Deere dealer.
UN26NOV90

DX,DRAIN 1903MAR931/1

10-16

101801

PN=22

TS1133

TS211

UN23AUG88

Safety

Service Cooling System Safely


Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

DX,RCAP 1904JUN901/1

Remove Accumulated Crop Debris


The build up of chaff and crop debris in the engine compartment, on the engine, and near moving parts is a fire hazard. Check and clean these areas frequently. Before performing any inspection or service, shut off the engine, set the parking brake and remove the key.

HX,AG,SF6793 1923AUG971/1

10-17

101801

PN=23

TS227

UN23AUG88

TS281

UN23AUG88

Safety Decal Location


Pictorial Safety Signs
At several important places of this machine safety signs are affixed intended to signify potential danger. The hazard is identified by a pictorial in a warning triangle. An adjacent pictorial provides information how to avoid personal injury. These safety signs, their placement on the machine and a brief explanatory text are shown below.

OUO6075,000189B 1928JUN011/1

Operators Manual
This operators manual contains all important information necessary for safe machine operation. Carefully observe all safety rules to avoid accidents.
UN06JUN01

OUO6075,000189C 1928JUN011/1

Repair and Maintenance


Before carrying out repair and maintenance work, shut off engine, set parking brake and remove key.

OUO6075,000189D 1928JUN011/1

15-1

101801

PN=24

H68390

UN06JUN01

H68389

TS231

1907OCT88

Safety Decal Location

Parking Brake
Set parking brake before leaving combine. Lock service brakes together before driving on roadway.
2907JUN01

German Only

OUO6075,000189E 1928JUN011/1

Front Access Ladder and Platform


Do not allow riders on access ladder or platform.

OUO6075,000189F 1928JUN011/1

Avoid Motor Vehicle Collisions


Avoid motor vehicle collision and serious injury or death. Always swing ladder to forward to locked position before driving combine on roadways.
UN26JUL01

OUO6075,00018A0 1928JUN011/1

15-2

101801

PN=25

H68393

H68392

UN06JUN01

H68391

Safety Decal Location

Rear Access Ladder and Service Platform


Do not allow riders on access ladder or platform.

OUO6075,0000005 1912JAN011/1

Fire Extinguisher
The machine must not be operated unless a fully-operational fire extinguisher is installed at this point. A minimum of 6 kg (15 lb.) general purpose fire extinguisher must be installed at this location.

OUO6075,00018A1 1928JUN011/1

Grain Tank
Never reach into grain tank or enter tank when the engine is running.

OUO6075,00018A2 1928JUN011/1

Header Drive Guard


Do not open or remove guard when the engine is running.

OUO6075,00018A3 1928JUN011/1

15-3

101801

PN=26

H68396

UN06JUN01

H68395

UN06JUN01

H68394

UN06JUN01

H65731

UN12JAN01

Safety Decal Location

Feeder House Shield


Before entering area of potential hazard, engage safety lock.

OUO6075,00018A4 1928JUN011/1

Feeder House Conveyor Chain


Potential hazard caused by rotating machine parts.

OUO6075,00018A5 1928JUN011/1

Feeder House Safety Stop


Before entering area of potential hazard, engage safety lock.

OUO6075,00018A6 1928JUN011/1

Elevators
Do not open or remove guard when the engine is running.

OUO6075,00018A7 1928JUN011/1

15-4

101801

PN=27

H68399

UN06JUN01

H68498

UN07JUN01

H68398

UN06JUN01

H68397

UN06JUN01

Safety Decal Location

Chopper
Do not touch any moving machine parts. Wait until all moving parts have stopped.

OUO6075,00018A8 1928JUN011/2

Stay clear of these components when the engine is running.

OUO6075,00018A8 1928JUN012/2

Grain Tank Unloading Auger


Do not touch any moving machine parts. Wait until all moving parts have stopped.

OUO6075,00018A9 1928JUN011/1

Hydraulic System
Avoid fluid escaping under pressure.

OUO6075,00018AA 1928JUN011/1

15-5

101801

PN=28

H68403

UN06JUN01

H68402

UN06JUN01

H68401

UN06JUN01

H68400

UN06JUN01

Safety Decal Location

Cooling System
Pressurized cooling system. Read the Operators Manual before servicing.

OUO6075,00018AB 1928JUN011/1

Rotary Screen and Radiator Fan


Keep hands away from Radiator Fan and Rotary Screen.

OUO6075,00018AC 1928JUN011/1

Feeder House Tilt Frame


Never reach into the crushing danger area as long as parts may move.

OUO6075,00018AD 1928JUN011/1

Electrical Power Lines


To avoid injury or death, keep sufficient distance away from electrical power lines.

OUO6075,00018AE 1928JUN011/1

15-6

101801

PN=29

H68407

UN06JUN01

H68406

UN06JUN01

H68405

UN06JUN01

H68404

UN06JUN01

Safety Decal Location

Rotary Screen
Keep hands away from Rotary Screen when engine is running.

OUO6075,00018AF 1928JUN011/1

Emergency Exit
Emergency exit. Pull tab, remove rope and push window.

OUO6075,00018B0 1928JUN011/1

Rear Door
Do not open door when combine is running.

OUO6075,00018B1 1928JUN011/1

15-7

101801

PN=30

H68410

UN06JUN01

H68409

UN06JUN01

H68408

UN06JUN01

Controls and Instruments


General View of Controls and Instruments

ACab Corner Post BMulti-Function Lever CArmrest Control Panel

DPark Brake Disengage Pedal

EPark Brake Engage Pedal FBrake Pedals

GSteering Column HGearshift Lever

OUO6075,00018B3 1928JUN011/1

20-1

101801

PN=31

H68142

UN23MAY01

Controls and Instruments

Switch and Knob Colors

AHC

IMPORTANT: When reversing, allow header to come to a complete stop before re-engaging. Before operating this combine for the first time, become familiar with the switches and controls. These controls are color coded to help you quickly locate them when operating the combine.

Yellow (A) - drive engagement. Black (B) - operating adjustments and controls. Orange (C) - ground drive and engine speed. Green (D) - activation indicators

OUO6075,00018B4 1928JUN011/1

20-2

101801

PN=32

H69000

UN27JUN01

Controls and Instruments

Armrest Control Panel

D
AHC

AHeader Engage Switch / Electro Feeder House Reverser Switch BSeparator Engage Switch

CHeader Height and Ground Pressure Knob DDIAL-A-SPEED Knob EEngine Speed Switches

FResponse Rate Control For Automatic Functions Knob GFeeder House Reaction Speed Knob

HCup Holder ICigarette Lighter

OUO6075,00018B5 1928JUN011/1

20-3

101801

PN=33

H68413

UN07JUN01

Controls and Instruments

Armrest Control Panel (Continued)

AHC

AGrain Tank Cover Switch BRoad Safety Switch CDraper Speed Switch DReel Speed Switch

EAutomatic Leveling Control (Optional) FManual Leveling Control (Optional)

GConcave Clearance Switch HFour Wheel Drive Speed Switch (Optional) ICylinder Speed Switch

JCleaning Fan Speed Switch KChopper Vane Adjust Switch (Optional)

OUO6075,00018B6 1928JUN011/1

20-4

101801

PN=34

H68414

UN07JUN01

Controls and Instruments

Multi-Function Lever

AForward/Reverse Lever BQuick-Stop Switch for Automatic Functions, Header

CUnloading Auger Swing DUnloading Auger Drive (with Indicator Light)

EActivation Buttons FReel Lift and Reel Fore/Aft Switch

GHeader Raise/Lower and Lateral Tilt Switch HAdjustable Hand-Rest

OUO6075,0000297 1911DEC001/1

20-5

PN=35

H68415
101801

UN07JUN01

Controls and Instruments

Corner Post

Continued on next page

OUO6075,00018B7 1928JUN011/2
101801

20-6

H68416

UN07JUN01

PN=36

Controls and Instruments


AAutomatic Combine Adjustment Display BHEADERTRAK Control Module CVISIONTRAK Display DTriple Display Tachometer EGREENSTAR Display Monitor (Attachment, see separate Operators Manual)

GREENSTAR is a trademark of Deere & Company.

OUO6075,00018B7 1928JUN012/2

20-7

101801

PN=37

Controls and Instruments

Overhead Control Panel


F

P
4/4

3/4

Delco Electrics

AUTO

DIM

SCAN

TM SET

JOHN DEERE
[TP] RT AF
PTY

RPT RDM

ALARM

AM FM U IIIL WX LOUD

AS

DSCN

RPT

RDM

1 2 3 4 5 6

REV

PAUSE

FF

4/4

3/4

ALight Switches BCLIMATRAK Control Switches (optional)

CElectrically Adjustable Outside Mirrors and Mirror Heater DRadio/Citizen Band (Special Equipment)

EWarning Display Panel FGREENSTAR Printer GWindshield Wiper and Windshield Washer

HHigh/Low Beam

NOTE: Dimensions for the installation of (D) are standard ones: 182 mm (7.17 in.) wide, 53 mm (2.1 in.) high.

CLIMATRAK is a trademark of Deere & Company GREENSTAR is a trademark of Deere & Company.

OUO6075,00003F9 1901JUN011/1

20-8

101801

PN=38

H68976

UN26JUN01

Controls and Instruments

Steering Column

B
A

ATrailer Signal Indicator Light BTurn Signal Indicator Light CBeacon Signal Indicator Light

DStarter Switch EVertical Steering Column Adjustment

FHorn GPedal for Horizontal Steering Column Adjustment

HTurn Signal Switch

OUO6075,00018B8 1928JUN011/1

20-9

101801

PN=39

H68418

UN07JUN01

Controls and Instruments

Header Engage / Electro Feeder House Reverser Switch (Yellow)


Turns header drive on/off. Push down and push forward to lock switch in the "on" position. Pull back to turn off. To engage electro feeder house reverser, pull back and hold down on reverser button. To engage header, road transport disconnect switch (A) must be in the field position. This switch must be OFF to start the engine. Header drive can also be shut off with the Quick Stop switch located on top of the multi-function lever. To re-engage the header if header and unloading auger are stopped with the Quick Stop switch, turn header switch off and then back on. Operator must be seated to operate header. If operator leaves seat after engagement, header will continue to operate for five seconds before it disengages. To re-engage, sit in seat then turn switch off and then back on.
ARoad Safety Switch

AHC

If the header fails to engage or stops unexpectedly, sit squarely on the seat, turn the switch off, push down and forward on switch to re-engage.

OUO6075,00018B9 1928JUN011/1

20-10

101801

PN=40

H68499

UN07JUN01

Controls and Instruments

Separator Engage Switch (Yellow)


Turns separator drive on/off. Road transport disconnect switch (A) must be in the field position. Push down and forward to lock switch in the on position. Pull to turn off. Switch must be in OFF position to start engine. The separator drive speed adjust and the cleaning fan speed adjust systems only work when the separator is running. The separator will disengage if the discharge beater speed drops below 300 rpm.
UN07JUN01

NOTE: Engage separator prior to the header.


ARoad Safety Switch

OUO6075,00018BA 1928JUN011/1

Header Height and Ground Pressure Knob (Black)


Controls set points for the header height and ground pressure system. See (Warning Devices and Monitors section).

OUO6075,00018BB 1928JUN011/1

20-11

101801

PN=41

H68420

UN07JUN01

H68419

Controls and Instruments

DIAL-A-SPEED Knob (Black) (Optional)


The DIAL-A-SPEED knob (A) controls the ratio of the reel speed to ground speed. To operate: 1. Start the engine and drive forward with the separator and header engaged. 2. Press the DIAL-A-SPEED button on the HEADERTRAK display. 3. Turn the knob and watch corner post display for desired setting. 4. Watch the speed of the reel and adjust the knob until you get the desired ratio to ground speed.
UN07JUN01

The reel will now speed up or slow down in relation to the ground speed. DIAL-A-SPEED system will not operate if ground speed is less than 1.2 km/h (0.75 mph). The minimum reel speed can be increased with the manual reel speed switch (B) when operating at less than 1.2 km/h (0.75 mph).

ADIAL-A-SPEED Knob BManual Reel Speed Switch

DIAL-A-SPEED is a trademark of Deere & Company

Continued on next page

OUO6075,0001984 1926JUL011/2

20-12

PN=42

H68421
101801

Controls and Instruments


To change the minimum speed: 1. Turn the DIAL-A-SPEED knob (A) counter clockwise until the HEADERTRAK corner post display reads zero. 2. Press the manual reel speed switch (B) to get the minimum reel speed desired. 3. Return the DIAL-A-SPEED knob to the prior setting and continue operating. This minimum speed is kept until the engine is shut off.
ADIAL-A-SPEED Knob BManual Switch

OUO6075,0001984 1926JUL012/2

20-13

H68423

UN07JUN01

101801

PN=43

H68422

UN07JUN01

Controls and Instruments

Engine Speed Switches (Orange)


Control engine rpm. For fast idle press switch (A) Rabbit.
A

For mid idle press switch (B). For slow idle press switch (C) Turtle.
B

OUO6075,00018BD 1928JUN011/1

Response Rate Control For Automatic Functions And Feeder House Reaction Speed Knobs
UN12NOV99

For details see HEADERTRAK Control Module, Section Warning Devices and Monitors.
AResponse Rate Control For Automatic Functions Knob BFeeder House Reaction Speed Knob

OUO6075,00013C7 1902FEB011/1

20-14

101801

PN=44

ZX018647

H68424

UN07JUN01

Controls and Instruments

Grain Tank Cover Switch (Black)


CAUTION: Grain tank covers must be closed before transporting combine on roads. IMPORTANT: Open grain tank covers before engaging separator. Actuator will not raise covers if tank is one third or more full. If grain tank is full, unload before raising covers. To open the grain tank covers push and hold the open-symbol (I). To close the grain tank covers push and hold the close-symbol (II). When covers are opened, the clean grain loading auger swings up with them. Auger swings down when covers are closed.
A
UN07JUN01

AGrain Tank Cover Switch IOpen-Symbol IIClose-Symbol

NOTE: For more details on operating the grain tank covers, (see Grain Tank Loading and Unloading System).

OUO6075,00018BE 1928JUN011/1

20-15

101801

PN=45

H68425

Controls and Instruments

Road Transport Disconnect Switch (Black)


The road transport disconnect switch must be in the road position when transporting the combine on the road. When switch (A) is pressed, the indicator light (B) will come on indicating the switch is in the road position. Pressing the switch will prevent the following functions. HEADERTRAK Control Functions Reel raise/lower and Reel fore/aft Unloading auger Auger swing Separator engage Header engage Header raise and lower

C AH

OUO6075,00018BF 1928JUN011/1

20-16

101801

PN=46

H65400

ARoad Transport Disconnect Switch BIndicator Light

UN18DEC00

To re-engage the above functions for field operation, press the road transport disconnect switch, then the desired function switch.

H68426

UN07JUN01

Controls and Instruments

Four Wheel Drive (Orange) (Optional)


IMPORTANT: To prevent damage to the hydrostatic system, do not switch 4-Wheel Drive on or off while driving combine in third gear (road gear) at maximum travel speed. Reduce speed to less than 1/2 of maximum. Turn 4-wheel drive off before going down a steep grade. When driving the combine in conditions which cause high pressures in the hydrostatic system and the combine slows down or stops, move multifunction lever to neutral and shift to a lower gear. It is ok to switch between low (turtle) and high (rabbit) settings on the GO while harvesting. Switch (A) control the 2-speed 4-wheel drive system. Press either switch once to engage and once to turn off. A lighted indicator (B) above each switch is on when the drive is engaged. Press the bottom switch (turtle) when more traction is required or the top switch (rabbit) when higher speeds are required. CAUTION: Ground speed will increase when disengaging four-wheel drive and will decrease when engaging four-wheel drive.
A4-Wheel Drive Control Switch BLighted Indicator

NOTE: For best overall performance it is recommended that the 2-speed 4-wheel drive be left in the low (turtle) speed mode. This will allow the machine to operate at maximum torque capacity.
It is NORMAL for front wheels to lose traction and spin out before the rear wheels in most conditions. In extremely muddy conditions, it may be necessary to apply both brakes momentarily to increase hydrostatic pressure to the 4-wheel drive motors. If rear wheels are spinning excessively shift from 2nd gear to 1st gear.

Continued on next page

OUO6075,0000241 1907DEC001/2
101801

20-17

H65350

UN18DEC00

PN=47

Controls and Instruments


When the drive is engaged, these approximate reductions in ground speed occur: First Gear: 20% Second Gear: 30% Third Gear: 50%

OUO6075,0000241 1907DEC002/2

Manual Reel Speed Switch (Black)


NOTE: Turn DIAL-A-SPEED off for manual control. If equipped with DIAL-A-SPEED, the automatic function can be overridden by the manual control, but will resume operation when the switch is released.
With header engage and separator engage switches on, push and hold plus (+) symbol to increase speed or push and hold minus (-) symbol to decrease speed.

OUO6075,00018C0 1928JUN011/1

Concave Clearance Switch (Black)


NOTE: When opening concave, go past set point then retract (close) concave to remove slack in linkage. This will prevent the concave from opening further then desired when crop material enters the machine.
The concave clearance switch adjusts concave clearance. Push plus (+) symbol for more clearance or push minus (-) symbol for less clearance.

OUO6075,00018C1 1928JUN011/1

20-18

H68429
101801

UN07JUN01

H68428

UN07JUN01

PN=48

Controls and Instruments

Cylinder Speed Switch (Black)


This switch controls the cylinder rpm. Cylinder must be running. Push and hold (+) symbol to increase speed or push and hold (-) symbol to decrease speed. Check rpm on the tachometer. This switch also inputs to the tachometer for cylinder speed alarm that is displayed in the overhead panel. Whenever speed is changed, the alarm is also reset. As system oil temperature increases, cylinder speed may increase about 30 rpm in four hours. Re-adjust cylinder speed as needed.

OUO6075,00018C2 1928JUN011/1

Cleaning Fan Speed Switch (Black)


NOTE: Separator must be running to adjust fan speed.
This switch adjusts the speed of the cleaning fan. Push and hold plus (+) symbol to increase speed or minus (-) symbol to decrease speed. The fan speed motor has a thermal (heat) shut off that will stop the motor from working if any of the following happen: Switch is used continuously for more than two or three minutes. Adjustment system is against the stop while the motor is still trying to change speed. Excessive binding or dragging in the linkage If any of the above causes are suspected, clean and adjust the system as necessary. Allow 10 to 15 minutes for the motor to cool, then try the switch again.

OUO6075,00018C3 1928JUN011/1

20-19

H68431
101801

UN07JUN01

H68430

UN07JUN01

PN=49

Controls and Instruments

Chopper Vane Adjust Switch (Black) (Optional)


Chopper vane adjust switch (A) controls the direction of the chopper vanes.

NOTE: Ignition must be on to adjust chopper vanes.


Push and hold symbol (I) to adjust chopper vanes to the left or push and hold symbol (II) to adjust chopper vanes to the right.
AChopper Vane Adjust Switch (Optional) IAdjust To The Left IIAdjust To The Right

OUO6075,000166C 1926APR011/1

Manual Leveling Control Switch (HILLMASTER II) (Optional)


Combine tilt adjustment is only possible with engine running and road safety switch (A) in field position.

H65355
AH C

UN18DEC00

ARoad Safety Switch in Field Position BManual Leveling Control Switch ICombine Tilt to the Left IICombine Tilt to the Right

OUO6075,00018C4 1928JUN011/1

20-20

101801

PN=50

ZX021818

UN13SEP00

H68432

NOTE: With automatic leveling control system activated, this switch can be used to overcome automatic functions, i.e. combine may be tilted manually (B) to the left or right.

UN07JUN01

Controls and Instruments

Automatic Leveling Control Switch (HILLMASTER II) (Optional)


The automatic leveling system will operate only with engine running and road safety switch (A) in field position. Pressing the switch (B) will activate the automatic leveling system. The indicator light (C) will come on indicating the switch is in automatic control position. CAUTION: Before driving combine on public roads, move switch to position (II) to make sure that a transport height of 4 m (13 ft 1 in.) is not exceeded.
ARoad Safety Switch in Field Position BAutomatic Leveling Control Switch CIndicator Light IAutomatic Leveling Control ON (field travel) IIAutomatic Leveling Control OFF (Road travel/Manual)
C AH

OUO6075,00018C5 1928JUN011/1

20-21

101801

PN=51

H67707

UN03MAY01

H68432

UN07JUN01

Controls and Instruments

Operating With HILLMASTER II Leveling System (Optional)


CAUTION: Particular care must be taken when turning the combine on slopes. Never turn combine faster than the leveling system can keep combine in level position. Always turn uphill! When the green indicator light (A) glows (tilt limit has been reached), take extreme care! IMPORTANT: Before actuating manual leveling control switch, make sure that parking brake is released. IMPORTANT: When parking the combine, do not park too close to other machines or walls of storage buildings. This is important as combine may tilt due to internal loss of oil pressure when parked for some time. This may cause damage to combine and adjacent machines or walls. The HILLMASTER II combine is designed for slopes up to 15%. The HILLMASTER II control box (B) is located on the left-hand side of the machine and uses an electronic tilt sensor to detect the slope.
UN13SEP00

OUO6075,0001687 1927APR011/1

20-22

101801

PN=52

ZX021821

ZX002438

UN16JUN95

ZX021820

UN13SEP00

Controls and Instruments

Daily Preparations Before Driving HILLMASTER II Combine (Optional)


Before driving the HILLMASTER II combine, the following tests have to performed for safety reasons. CAUTION: Do not attempt to operate HILLMASTER II combine unless all tests are OK! If one of the following tests failed, contact your John Deere dealer. Requirements: Engine running (high speed) Road safety switch in field position Parking brake released Automatic leveling control switch in OFF position.
UN03MAY01

OUO6075,0001686 1927APR011/4

1. Test 1: Move manual leveling control switch to right-hand tilt position for 20 secondscombine should tilt to the right.
UN13SEP00

OUO6075,0001686 1927APR012/4

2. Test 2: Move manual leveling control switch to left-hand tilt position for 20 secondscombine should tilt to the left.
UN13SEP00

Continued on next page

OUO6075,0001686 1927APR013/4
101801

20-23

PN=53

ZX021823

ZX021822

H67708

Controls and Instruments


3. Test 3: By operating manual leveling control switch, bring combine from maximum left tilt to maximum right tilt the time required to do this should be 57 seconds.
UN03MAY01

OUO6075,0001686 1927APR014/4

Operating With Automatic Leveling Control (Optional)


When working in the field, place road safety switch (A) to field position (the indicator light (B) will go off) and place leveling control switch (C) to position for automatic operation (the indicator light (D) will come on). Press manual leveling control switch (E) alternatively on the left-hand and right-hand side to raise the machine in working position. Now the combine will automatically level on slopes up to 15%.
ARoad Safety Switch BIndicator Light CAutomatic Leveling Control Switch DIndicator Light EManual Leveling Control Switch

OUO6075,0001685 1927APR011/1

20-24

101801

PN=54

H67710

UN03MAY01

H67709

Controls and Instruments

Operating With Manual Leveling Control (Optional)


Use the manual leveling control switch (A) to manually tilt the combine or to place combine to the road travel position. 1. To Manually Tilt the Combine: Place road safety switch (B) in field position (the indicator light (C) will go off) and place automatic leveling control switch (D) to OFF position (the indicator light (E) will go off). Press manual leveling control switch (A) on the left-hand or right-hand side to tilt the machine as desired.
AManual Leveling Control switch BRoad Safety Switch CIndicator Light DAutomatic Leveling Control switch EIndicator Light

OUO6075,0001684 1927APR011/2

2. To Place Combine to Road Travel Position: Place road safety switch (B) in field position (the indicator light (C) will go off). Press and hold automatic leveling control switch (D) to ON position (the indicator light (E) will come on). Press manual leveling control switch (A) either on the left-hand and right-hand side to lower the machine to road travel position.
AManual Leveling Control switch BRoad Safety Switch CIndicator Light DAutomatic Leveling Control switch EIndicator Light

OUO6075,0001684 1927APR012/2

20-25

101801

PN=55

H67712

UN03MAY01

H67711

UN03MAY01

Controls and Instruments

Multi-Function Lever
IMPORTANT: If the hydro charge pressure light comes on in the warning display panel when the lever is moved, check hydrostatic/hydraulic oil level or replace filter. If this does not correct the problem, see your John Deere dealer. Move lever forward to go forward.
UN07JUN01

Move lever to the right and rearward to go backward. The palm rest (A) is adjustable with three detented positions. To lower the palm rest, release lever (B) under the palm rest. To raise the palm rest, release lever (B) and lift the palm rest.

APalm Rest BLever

OUO6075,00018C6 1928JUN011/1

Quick Stop Switch (Yellow)


IMPORTANT: Header drive can be disengaged by this switch in case of malfunctions. The quick stop switch (A) shuts off the header engage (B), unloading auger drive (C) and unloading auger swing (D) at the same time. Press switch once to stop these drives simultaneously. Unloading auger drive can be restarted by pushing the button in the multi-function. To re-engage the header drive, turn header switch off and on.
AQuick Stop Switch BHeader Engage Switch CUnloading Auger Drive Button DUnloading Auger Swing Switch

A
D

C B

OUO6075,00018C7 1928JUN011/1

20-26

101801

PN=56

H68439

UN07JUN01

H68438

Controls and Instruments

Unloading Auger Swing Switch (Black)


To swing the auger, the road transport disconnect switch (A) must be in field position. Auger swing control can be either manual or automatic. Press top of switch (B) to swing auger out. Press bottom of switch to swing auger in. For manual control, press the switch down part way and hold until auger reaches the desired position. The auger stops when the switch is released.
A

NOTE: If the auger automatic swing switch is operated while raising or lowering the feeder house, the auger swing cylinder may become starved for oil and stop working after two seconds. To complete auger swing press the auger swing switch until the auger has completed swinging.
For automatic control, press the switch all the way down and release it. The auger will swing to the full out or full in position without holding the switch.

ARoad Transport Disconnect Switch BTop of Switch

NOTE: The automatic auger swing function will not operate when the unloading auger drive is engaged.

OUO6075,00018C8 1928JUN011/1

20-27

101801

PN=57

H68440

UN07JUN01

Controls and Instruments

Unloading Auger Drive Switch (Yellow)


C

To engage the unloading auger drive, the road transport disconnect switch (A) must be in field position.
B

Pressing switch (B) turns the unloading auger drive on/off. The switch has a lighted indicator that comes on when the drive is engaged. The unloading drive can also be turned off with the Quick Stop switch (C) on the top of the multi function lever. The unloading drive will engage only while the button switch is held in while the auger is in the auto-swing mode out or when the auger is manually swung out less than 50%. To re-engage the unloading auger if the header and unloading auger are stopped with the Quick Stop switch, press the unloading switch once.
ARoad Transport Disconnect Switch BUnloading Auger Drive Switch CQuick Stop Switch
UN07JUN01

OUO6075,00018C9 1928JUN011/1

20-28

101801

PN=58

H68441

Controls and Instruments

Activation Buttons (Black)


When pressing any of the buttons (A), (B) or (C), the following functions are performed: Return to Cut or Stubble Height Mode The electronic control system will move the header back to preselected positions.
B

NOTE: All header positions obtained by pressing buttons (A), (B) or (C) may be overcome by pressing switches (D) or (E).
The activation buttons can be activated only when: 1. A properly equipped header is connected to the combine. 2. The engine is running. 3. The road transport disconnect switch is in the field position. 4. HEADERTRAK mode is enabled. 5. The header engage switch is engaged. The system is activated by pressing the header activation buttons in the multi-function lever. The header control system will then take control and move the header to the selected position.

AActivation Button 1 BActivation Button 2 CActivation Button 3 DReel Lift and Reel Fore/Aft EHeader Raise and Lower and Lateral Tilt Switch

OUO6075,00018CA 1928JUN011/1

20-29

PN=59

H68442
101801

UN07JUN01

Controls and Instruments

Activation Button Allocation

The top of the table shows the activated function. The lower part of the table shows the allocation of the activation buttons with the appropriate functions.

OUO6075,00018CB 1928JUN011/1

20-30

PN=60

H68443
101801

UN07JUN01

ZX018692

UN12NOV99

Controls and Instruments

Reel Lift/Reel Fore and Aft Switch (Black)


To operate reel lift/reel fore aft switch (A), the road safety switch (B) must be in field position. Push and hold bottom of switch to raise reel. Push and hold top of switch to lower reel. Push and hold left side of switch to move reel forward. Push and hold right side of switch to move reel rearward. If the HEADERTRAK Control or automatic auger swing are operating when this switch is used, the reel response may vary.
AReel Lift and Reel Fore/Aft Switch BRoad Safety Switch

OUO6075,00018CC 1928JUN011/1

Header Lift Switch (Black)


To raise or lower the header (A), the road transport disconnect switch (B) must be in field position.
A

Press and hold top of switch to raise header. Press and hold bottom of switch to lower header.
AHeader Lift Switch BRoad Transport Disconnect Switch

OUO6075,00018CD 1928JUN011/1

20-31

101801

PN=61

H68445

UN07JUN01

H68444

UN07JUN01

Controls and Instruments

Lateral Tilt Switch (Black)


To manually operate lateral tilt switch (A), the road transport disconnect switch (B) must be in field position.
A

Press right side of switch to tilt right side of header down. Push left side of switch to tilt left side of header down.
ALateral Tilt Switch BRoad Transport Disconnect Switch

OUO6075,00018CE 1928JUN011/1

20-32

101801

PN=62

H68446

UN07JUN01

Controls and Instruments

CLIMATRAKAutomatic Temperature Control


The CLIMATRAK system consists of a temperature selector knob (A), mode selector switch (B), a fan speed control knob (C), and a solar sensor (D).
UN03JUL01

With the mode selector switch in the OFF position (bottom of switch pressed in), all power to the air conditioning system will be off. In the ON position (middle position), power is supplied for normal functions. In the DEFOG position (top of switch pressed in), power is supplied to the compressor regardless of temperature selection to remove moisture from the air even in the heat mode. The recirculation fan controls air coming out of the louvers. Fan speed control switch controls an infinitely variable fan. It also has a detent position for automatic fan speed operation. In this position, fan speed is determined by the difference between the selected temperature and actual cab temperature. As temperature approaches the set point, fan speed decreases. The desired cab temperature is selected with the temperature selector knob. Turn knob to desired temperature setting.
ATemperature Selector Knob BMode Selector Switch CFan Speed Control Knob DSolar Sensor

CLIMATRAK a trademark of Deere & Company

OUO6075,0001869 1921JUN011/1

20-33

101801

PN=63

H68447

UN07JUN01

H68834

Controls and Instruments

Outside Mirror Control Switch


The right and left-hand side rear view mirrors are adjusted by moving the remote mirror control switch (A) located in the overhead display panel. Move mirrors up/down or to the right/left according to arrows on switch.
AMirror Control Switch IAdjusting Left-hand Outside Mirror IIAdjusting Right-hand Outside Mirror
UN05NOV99

OUO6075,0000038 1922JAN011/1

Mirror Heater Switch


Switching on mirror heater is only possible when starter switch is in On position.
IMirror Heater Off IIMirror Heater On
UN04NOV99

OUO6075,00018CF 1928JUN011/1

20-34

101801

PN=64

ZX018654

ZX018653

UN04NOV99

ZX018652

Controls and Instruments

Windshield Wiper and Windshield Washer (Optional)


The windshield wiper and washer are controlled by switch (A). Move the switch to the center position (B) to operate the windshield wipers.
A

The windshield wiper can be stopped on either side of glass, depending on when the switch is returned to the off position. To operate the windshield washer move the switch to the top position (C). The key switch must be in the on position for the wiper to work.
AOff BWindshield Wiper CWindshield Washer (optional)

OUO6075,00003F8 1923MAY011/1

Gear Shift Lever


IMPORTANT: Stop the combine and move ground speed drive lever to neutral before shifting from one gear to another. When shifting with the gear shift lever (A), the shift is a straight line pattern with detents for 1, 2 and 3. Less resistance is felt for neutral between 1st and 2nd gears.
AGear Shift Lever
UN07JUN01

H68144

UN23MAY01
101801

OUO6075,00018D0 1928JUN011/1

20-35

PN=65

H68585

Controls and Instruments

Horn
CAUTION: For safety reasons, sound horn before starting the engine or operating the combine. Press button (A) to sound horn.
AHorn
UN06JUN01

OUO6075,00018D1 1928JUN011/1

Indicator Lights
Trailer signal indicator light (A) will illuminate when trailer harness is hooked up and turn signal is applied.
UN20MAR01

Turn signal indicator light (B) will illuminate when turn signal is applied. Beacon signal indicator light (C) will illuminate when beacon light switch is turned on.
ATrailer Signal Indicator Light BTurn Signal Indicator Light CBeacon Signal Indicator Light

OUO6075,00015A1 1921MAR011/1

20-36

101801

PN=66

H66894

H68448

Controls and Instruments

Start Switch
CAUTION: Sound horn before starting engine to clear people away from the combine. To avoid the possibility of personal injury or death, start the engine ONLY from the operators seat. Do not start engine by shorting across starter terminals. Combine will start in gear if normal circuit is bypassed. Start switch is located on right side of steering column. Key positions are:
First Position (O) .............................................................................. Off Second Position (I) ........................................................... Accessories Third Position (II) ............................................... Accessories and Run Fourth Position (III) ....................................................................... Start

When released, it will return to run or third position. If engine will not crank, check for: Multi-function lever in neutral Separator OFF Header OFF Auger swing switch in neutral Unloading auger OFF

ADecal

OUO6075,0000050 1917NOV001/1

20-37

101801

PN=67

ZX018660

UN26NOV99

The decal (A) on the storage box lid shows engine starting information.

ZX018659

UN04NOV99

Turn key to the fourth position to start. All lights on the warning display panel will come on.

Controls and Instruments

Shifting Feeder House/Header Reverser


IMPORTANT: Reel must be raised before engaging reverser. Backing out a crop "slug" into a turning reel will bend it. Allow header to come to a complete stop before shifting feeder house reverser. 1. Stop header by switching off yellow header drive switch. 2. Throttle engine to slow idle. 3. Pull back and hold down on electro feeder house reverser button. 4. Release feeder house button as soon as feeder house is free of "slug". 5. Throttle engine to high idle. 6. Resume harvesting. IMPORTANT: During reverser operation, never attempt to force slugs through combine by repeated cycling of reverser drive. Repeated cycling shortens life of components.
UN07JUN01

OUO6075,00018D2 1928JUN011/1

20-38

101801

PN=68

H68451

UN07JUN01

H68450

Warning Devices and Monitors


Overhead Warning Display Panel

4/4

3/4

These lights monitor the most important combine functions (road and operating safety, engine). Warning display panel shows a red, yellow or green light and sounds a buzzer for the following conditions. Priority 1: Red warning light with acoustical warning signalStop engine at once and correct problem. Priority 2: Yellow warning light with acoustical warning signal Service or correct problem. Stop engine as required.

Priority 3: Green warning light with acoustical warning signalBe aware of condition.

NOTE: When key is in start position, all lights on the panel will come on. These warning lights dim at night when the field or road lights are on.

OUO6075,00018D3 1928JUN011/1

25-1

101801

PN=69

H68975

UN26JUN01

Warning Devices and Monitors

Unloading Auger On
Green light will come on, buzzer will sound three short pulses, a 15 second pause and then repeat.
UN04MAR99 H52365

AG,OUO1035,607 1910MAY991/1

Low Fuel
The fuel level low light will be come on and the buzzer will sound four beeps every five minutes until fuel is added. The alarm will sound when the fuel level reaches 11% of remaining fuel (approximately one hour of field operation).

H52366

UN04MAR99

AG,OUO1035,755 1925JUN991/1

Parking Brake On
Yellow light on whenever the parking brake is depressed. The buzzer will sound steadily if the multi-function lever is out of neutral.
UN04MAR99 H52367

OUO6075,000150E 1921FEB011/1

Main Gearcase Drive Filter


Yellow light on. Buzzer sounds four beeps every five minutes until error is corrected.
UN04MAR99 H52368

Replace oil filter.

AG,OUO1035,757 1925JUN991/1

25-2

101801

PN=70

Warning Devices and Monitors

Main Gearcase Temp


Yellow light on and buzzer sounds steadily when oil in the gearcase reaches 93 C (200F). Check oil level and clean oil cooler. If the light still stays on, see your John Deere dealer.
UN04MAR99 H52369

AG,OUO1035,758 1925JUN991/1

Hydraulic Oil Temp


Yellow light comes on and the buzzer sounds steadily. Clean oil cooler and check oil level in main hydraulic reservoir. If the light still stays on, see your John Deere dealer.
UN04MAR99 H52370

AG,OUO1035,759 1925JUN991/1

Voltage
Yellow light on and buzzer sounds steadily if voltage drops below 10 volts and will stay on until voltage increases to 11 volts. Check wiring, alternator belt, batteries and cables. This light may come on for a short period of time after starting the engine, if the batteries are low. If the light still stays on, see your John Deere dealer.

H52371

UN04MAR99

AG,OUO1035,760 1925JUN991/1

25-3

101801

PN=71

Warning Devices and Monitors

ENG (Engine) Air Filter


Yellow light comes on when engine air filter is plugged. Buzzer sounds three beeps every 30 minutes until the problem is corrected. Clean or replace primary filter element. Replace safety element only if needed. If the light still stays on, see your John Deere dealer.
UN04MAR99 H52372

AG,OUO1035,761 1925JUN991/1

Separator Plugged
Yellow light on and buzzer sounds after two seconds when walkers are plugged. Clean off walkers. Light must be on for two seconds to sound buzzer. Header drive must be on to turn on the system. If the light still stays on, check switch adjustment (over walkers). If the light still stays on, see your John Deere dealer.
UN07JUN91 H43345

HX,AG,SF6806 1925JUN991/1

Tilt Limit (HILLMASTER II )


Green light comes on as soon as maximum tilt position has been reached (with leveling system switched on).

OUO6075,0001776 1931MAY011/1

25-4

H68011

UN31MAY01

101801

PN=72

Warning Devices and Monitors

Grain Tank Cover Indicator


Indicates that the grain tank covers are opened.

H68376

UN01JUN01

OUO6075,0001777 1931MAY011/1

Grain Tank Full


Green light comes on and buzzer sounds three short pulses when grain tank is full. The light stays on until tank is emptied. Sensor must be tripped for two seconds to turn on light. If the header switch is off, then the buzzer will not sound but the light will stay on. If the light still stays on after the grain tank is empty, check switch paddle in tank for free movement and clean if necessary. If the light still stays on, see your John Deere dealer.

AG,OUO1035,540 1905MAY991/1

Grain Tank (3/4) Full


Green light comes on when grain tank is 3/4 full.

OUO6075,00018D4 1928JUN011/1

25-5

101801

PN=73

ZX018665

UN15NOV99

ZX018666

UN15NOV99

Warning Devices and Monitors

Hydro Charge Pressure


Red light on and buzzer pulsates after four seconds. Stop engine and check oil level in the reservoir. Add oil as needed or change filter. If the light still stays on, see your John Deere dealer.
UN04MAR99 H52374

AG,OUO1035,763 1925JUN991/1

Main Gearcase Lube Pressure


Red light on and buzzer pulses. Stop engine and check oil level in the reservoir. Add oil as needed. If warning continues, change filter. If the light still stays on, see your John Deere dealer.
UN04MAR99 H52375

OUO6075,000003A 1922JAN011/1

ENG (Engine) Temperature


Red light on and buzzer pulses. Stop engine and check: radiator coolant level plugged radiator or rotary screen leaking hoses broken fan belt correct engine fan speed (see Service-Engine section)

H52376

If the light still stays on, see your John Deere dealer.

UN04MAR99

OUO6075,0000052 1917NOV001/1

25-6

101801

PN=74

Warning Devices and Monitors

ENG (Engine) Oil Pressure


Red light on and buzzer pulses if oil pressure drops below 2 bar (25 psi). Stop engine and check oil level, lines and filter.

If the light still stays on, see your John Deere dealer.

H52377

NOTE: This sensor also provides the interlock so the header lift, reel lift, reel fore/aft, and HEADERTRAK will not function unless the engine is running.

UN04MAR99

OUO6075,000151B 1921FEB011/1

High Beam Indicator


Indicates when the high beam lights are selected for use.

OUO6075,0001778 1931MAY011/1

Straw Chopper (Optional)


Yellow light on and buzzer sounds steady if the straw chopper is running below 85 % of its proper speed. Header drive must be on and the operator must be in the seat. Stop engine, inspect drives and look for plugging.

H52379

UN04MAR99

H68012

UN31MAY01

HX,AG,SF6812 1925JUN991/1

25-7

101801

PN=75

Warning Devices and Monitors

Grain Separator
Yellow light on and buzzer sounds steadily if the straw walkers are running below 85 % of their proper speed. Header drive must be on and the operator must be seated. Stop engine, inspect drives and look for plugging. (See Troubleshooting section of this manual).

H43708

UN06AUG91

HX,AG,SF6813 1925JUN991/1

Auger Conveyor
Yellow light on and buzzer sounds steadily if the augers are running below 85 % of their proper speed. Header drive must be on and the operator must be seated. Stop engine, inspect drives and look for plugging. (See Troubleshooting section of this manual).

H52380

UN04MAR99

HX,AG,SF6814 1925JUN991/1

Grain Elevator
Yellow light on and buzzer sounds steadily if the clean grain elevator is running below 85 % of its proper speed. Header drive must be on and the operator must be seated. Stop engine, inspect drives and look for plugging. (See Troubleshooting section of this manual).

H52381

UN04MAR99

HX,AG,SF6815 1910MAY991/1

Tailings Elevator
Yellow light on and buzzer sounds steadily if the tailings elevator is running below 85 % of its proper speed. Header drive must be on and the operator must be seated. Stop engine, inspect drives and look for plugging. (See Troubleshooting section of this manual).

H52382

UN04MAR99

HX,AG,SF6816 1925JUN991/1

25-8

101801

PN=76

Warning Devices and Monitors

Cylinder Speed
Yellow light on and buzzer sounds steadily if rpm drops to less than 80 % of current setting of cylinder speed. Engine must be running, header drive must be on, and cylinder drive must be above 90 rpm to work. When the light and buzzer come on, stop engine and check for plugging. The sensor behind the cylinder sheave should be a half turn from contacting the tone wheel. If the light still stays on, see your John Deere dealer.

NOTE: Cylinder speed light will not come on when reducing engine speed to low idle. Engine speed must be steady when cylinder speed drops for warning light to come on.

H52383

UN04MAR99

HX,AG,SF6817 1925JUN991/1

Engine Speed
Yellow light on and buzzer sounds if rpm drops below 2000 on the Combine.
UN04MAR99 H52384

When the light and buzzer come on, reduce the load on the engine. If the light still stays on, see your John Deere dealer.

HX,AG,SF6818 1910MAY991/1

25-9

101801

PN=77

Warning Devices and Monitors

HEADERTRAK Control Module


ADisplay BStubble Height Switch CReturn to Cut Switch DHeader Width Switch EHEADERTRAK Enable/Disable Switch FHeader Ground Pressure (Float) Switch GReel Resume Switch HDial-A-Speed Switch

OUO6075,00018D5 1928JUN011/1

25-10

101801

PN=78

H68452

UN27JUN01

Warning Devices and Monitors

HEADERTRAK Control Display


A indicates the header height or pressure relative to the ground B appears if stubble height mode is enabled C appears if return to cut mode is enabled D indicates which activation button is pressed E indicates the full or part of header width F shows the header position relative to the ground or header lift pressure, shows reel speed ratio (when adjusted) and shows header width or number of rows (when adjusted). (For cutting platforms units are meters for metric system and feet for English system) G appears if ground pressure mode is enabled H appears if reel resume mode is enabled I appears if HEADERTRAK mode is enabled J appears if any mode is activated Only one mode can be activated, Stubble Height Control (B), Return to Cut (C) or Ground Pressure (G) is indicated by arrows. If any of the above modes is activated, reel resume and lateral tilt will be activated too, if enabled.

AHeader Height or Pressure Bar Graph Indicator BStubble Height Control Icon CReturn to Cut Icon DActivation Button 1, 2 or 3 Display EHeader Width Icon FHeader Width GGround Pressure Icon HReel Position Icon IHeader Tilt Angle JArrows

OUO6075,00018D6 1928JUN011/1

25-11

101801

PN=79

H68453

UN06JUN01

Warning Devices and Monitors

Description of HEADERTRAK Control System


The HEADERTRAK Control system compensates for uneven ground and controls the horizontal and vertical position of the header. The system continuously compares the preset position and the actual position and thus keeps the header in the desired working position. Desired values are entered by means of the rotary potentiometers. Information about the actual position come from the potentiometers on the components. The control board processes both signals and adjusts the headers position accordingly by means of the hydraulic system. Horizontal Adjustment There are two operating modes for the horizontal adjustment: Manual adjustment In this mode the hydraulic components are directly activated via the multi-function lever. Automatic adjustment In this mode the parallel adjustment of the header in relation to the ground is carried out via skid plates. This ensures that the distance between the header and the ground is equal on both the left-hand and right-hand sides. Vertical Adjustment There are four operating modes for the vertical adjustment: Manual adjustment In this mode the hydraulic components are directly activated via the multi-function lever. Automatic adjustment In this mode the parallel adjustment of the header in relation to the ground in a range of 0 to 250 mm (0 to 9.84 in.) is carried out via skid plates. This ensures that the header height is always constant.

Continued on next page

OUO6075,00018DD 1928JUN011/4
101801

25-12

PN=80

H68468

UN07JUN01

H68467

UN06JUN01

Warning Devices and Monitors


Header height At heights above 250 mm (9.84 in.) the position of the header is controlled with the feeder house height potentiometer. Float control In this mode the pressure exerted on the ground by the header can be preset.

Continued on next page

OUO6075,00018DD 1928JUN012/4

25-13

101801

PN=81

ZX018981

UN15NOV99

Warning Devices and Monitors


NOTE: It is possible to override all the automatic modes manually.
Response Rate Control For Automatic Functions
UN12NOV99

Potentiometer (A) controls the response rate of the header raise/lower functions when in the automatic modes. Requirements: Engine running Road safety switch in field position Header drive enabled Operation: Press switch (B) to enable stubble height control. Press stubble height control button (C) to lower the header to the preselected position and to activate stubble height control. Then use response rate potentiometer (A) to adjust the rate at which header follows ground contours. Turn clockwise - Increase response rate. Turn counterclockwise - Decrease response rate.
APotentiometer, Response Rate Control (Automatic Functions) BStubble Height Control Enable Switch CStubble Height Control Activated Switch

Continued on next page

OUO6075,00018DD 1928JUN013/4
101801

25-14

PN=82

H68470

UN07JUN01

H68469

UN06JUN01

ZX018979

Warning Devices and Monitors


Response Rate Control For Manual Functions Potentiometer (A) controls the response rate (from 4 to 12 seconds) of the header raise/lower full range movement when in the manual mode (with or without HEADERTRAK control function activated). Requirements: Engine running Road safety switch in field position Header drive enabled Stubble height control switch (B) activated or deactivated

Operation: Use response rate potentiometer (A) to adjust the rate at which header will react when being raised or lowered by switch (C). Turn clockwise - Increase response rate. Turn counterclockwise - Decrease response rate.
APotentiometer, Response Rate Control (Manual Functions) BStubble Height Control Enabled Switch CHeader Lift Switch

OUO6075,00018DD 1928JUN014/4

25-15

PN=83

H68471
101801

UN07JUN01

H68469

UN06JUN01

ZX018980

UN12NOV99

Warning Devices and Monitors

Stubble Height Control


Stubble Height Control allows the operator to select the position of the header relative to the ground, follow the ground contour, and return to that position automatically. The system must be calibrated for each header that is used with the combine, (see Calibration Procedures section). Activation buttons 1, 2 and 3, located on the multi-function lever, can be used for selecting three different header heights.

NOTE: If both Stubble Height Control and Return to Cut are enabled, activation button 1 will activate Return to Cut. Activation buttons 2 and 3 will be assigned to Stubble Height Control.
Height is controlled via the potentiometers on the cutting platform skids when in the range 0-250 mm (0-9.84 in.). Operation: Stubble Height Control mode can be activated only when: 1. A properly equipped header is connected to the combine 2. The engine is running 3. The road safety switch is in the field position 4. Stubble Height Control mode is enabled 5. The header engage switch is engaged
1Activation Button 2Activation Button 3Activation Button

Continued on next page

OUO6075,00018D7 1928JUN011/2

25-16

PN=84

H68443
101801

UN07JUN01

H68454

UN06JUN01

Warning Devices and Monitors


The system is enabled by pressing switch (A) on the corner post display unit. Symbol (B) will appear on the display. Activate the system by pressing one of the activation buttons 1, 2 or 3 on the multi-function lever. Arrows (C) on each side of the symbol indicate that the system is active. The number (D) in the lower left corner of the display indicates which activation button was pushed. To change the height setpoint (E) of any of the activation buttons, press the desired activation buttons and adjust the height using the header height and ground pressure knob (F) to move the height setpoint and to move the header up or down. Turning the knob towards the (+) symbol will raise the header. Turning the knob towards the (-) symbol will lower the header. Bar graph (G) and number display (H) show the position of the header, based on the height sensor on the header. Manually raising the header with switch (I) on the multi-function lever will turn off the function. Pressing any of the activation buttons will re-activate the system and the header will move to the selected height. The system can be disabled by pressing switch (A).
AStubble Height Control Switch BStubble Height Control Symbol CArrows DDisplay Number EHeight Setpoint FHeader Height and Ground Pressure Knob GBar Graph HNumber IHeader Raise/Lower Switch
UN06JUN01

OUO6075,00018D7 1928JUN012/2

25-17

PN=85

H68456
101801

UN07JUN01

H68455

Warning Devices and Monitors

Return To Cut
Return to Cut control allows the operator to select the position of the feeder house in relation to the combine and return to that position automatically. The system must be calibrated for each header that is used with the combine, (see Calibration Procedures section). Activation buttons 1, 2 and 3 located on the multi-function lever can be used for selecting three different header heights.

NOTE: If both Return to Cut and Stubble Height Control are enabled, activation button 1 will activate Return to Cut. Activation buttons 2 and 3 will be assigned to Stubble Height Control.
The Return to Cut control is controlled via the feeder house height potentiometer when in the range above 250 mm (9.84 in.). Operation: The Return to Cut mode can be activated only when: 1. A properly equipped header is connected to the combine. 2. The engine is running. 3. The road safety switch is in the field position. 4. Return to Cut mode is enabled. 5. The header engage switch is engaged.
1Activation Button 2Activation Button 3Activation Button
UN07JUN01

Continued on next page

OUO6075,00018D8 1928JUN011/2

25-18

PN=86

H68443
101801

H68457

UN06JUN01

Warning Devices and Monitors


The system is enabled by pressing switch (A) on the corner post display unit. Symbol (B) will appear on the display. Activate the system by pressing one of the activation buttons 1, 2 or 3 on the multi-function lever. Arrows (C) on each side of the symbol indicate that the system is active. The number (D) in the lower left corner of the display indicates which activation button was pushed. To change the height setpoint (E) of any of the activation buttons, press the desired button and adjust the height using the header height and ground pressure knob (F) to move the height setpoint. Turning the knob towards the (+) symbol will raise the header. Turning the knob towards the (-) symbol will lower the header. Bar graph (G) and number display (H) show the relative position of the header, based on the Return to Cut sensor linked to the feeder house. Manually adjusting the header height with switch (I) on the multi-function lever will deactivate the system. Pressing any of the activation buttons will re-activate the system and the header will move to the pre-selected height. The system can be disabled by pressing switch (A).
AReturn to Cut Switch BReturn to Cut Symbol CIndicator Arrows DNumber EHeight Setpoint FHeader Height and Ground Pressure Knob GBar Graph HNumber IHeader Raise/Lower Switch
UN06JUN01

OUO6075,00018D8 1928JUN012/2

25-19

PN=87

H68456
101801

UN07JUN01

H68458

Warning Devices and Monitors

Header Width
Header width display and units for calibration For cutting platforms the header width will be displayed on the lower line of the triple display tachometer Units are meters for metric system and feet for English system For row crop headers the number of rows will be displayed on the middle line and the row spacing on the lower line of the triple display tachometer Row spacing units are mm for metric system and inches for English system Each pressing of switch (A) will reduce header width by 25 % (if equipped with cutting platform) or reduce the numbers of rows by one row (if equipped with row crop header).
UN06JUN01

If the header width is reduced, the arrows of the header width symbol (B) will face in the opposite direction (C). Pressing and holding switch (A) for 2 seconds will set the header width back to full width. Header width is also returned to full width whenever a stop count message is generated by raising the header.

NOTE: To set header width or harvesting threshold, (see Calibration Procedures section.

AHeader Width Switch BHeader Width Symbol CArrows of Width Symbol

OUO6075,00018D9 1928JUN011/1

25-20

101801

PN=88

H68459

Warning Devices and Monitors

DIAL-A-SPEED
The operator enables the DIAL-A-Speed system by using button (A) in the Cornerpost display. The double arrow under the DIAL-A-SPEED icon (B) will appear on the display. The DIAL-A-SPEED system can be activated only when: The engine is running A properly equipped header is connected to the combine The header is engaged The header has been calibrated The operator activates the system by pressing one of the Header Activation Buttons on the multi-function lever. Arrowheads on each side of the icon indicate the system is activated. Manually raising the header will deactivate the system immediately if the Stubble Height Control system is also active. If DIAL-A-SPEED is the only system active, raising the header for 1.5 Seconds (adjustable) will deactivate the system. Pushing any of the Header Activation Buttons will reactivate the system. The operator disables the system by pushing the DIAL-A-SPEED Enable Button in the corner post display. If all of the above conditions have been met, the system will control the reel speed to the ratio selected. Rotating the DIAL-A-SPEED knob (located on the armrest control panel) clockwise will increase the ratio and counterclockwise will decrease the ratio. The larger the ratio number (C) selected, the faster the reel will operate with respect to combine ground speed. The selected ratio will be displayed numerically on the Cornerpost display.

ADIAL-A-SPEED Button BDIAL-A-SPEED Icon CNumber

OUO6075,00018DA 1928JUN011/1

25-21

H68835

UN03JUL01

101801

PN=89

Warning Devices and Monitors

Lateral Tilt

H46238

UN10DEC94

Lateral tilt maintains the horizontal header position relative to the ground. It uses sensors to determine height at each end of the header. Lateral tilt, tilts the header +/- 4 degrees to equalize the distances to the ground at each end of the header. If the combine is equipped with Stubble Height Control, they work together to maintain the closest position of the cutterbar to the ground. The system must be calibrated for each header that is used with the combine, (see Calibration Procedures section).

If the Return to Cut and Stubble Height Control systems are disabled, lateral tilt will still operate. If the lateral tilt system is disabled, Return to Cut and Stubble Height Control will still operate. Operation: 1. A properly equipped header is connected to the combine 2. The engine is running 3. The road safety switch is in the field position 4. Lateral Tilt mode is enabled 5. The header engage switch is engaged

Continued on next page

OUO6075,0001978 1924JUL011/2

25-22

101801

PN=90

H68460

UN06JUN01

Warning Devices and Monitors


The system is enabled by pressing switch (A) on the corner post display unit. Symbol (B) will appear on the display. Arrows (C) on each side of the symbol indicate that the system is active. Pressing switch (D) or header raise/lower switch will turn off lateral tilt system. Press the right side of the switch to tilt header to the right. Press the left side of the switch to tilt header to the left. Pressing any of the activation buttons will re-activate the system. The system can be disabled by pressing switch (A).
ALateral Tilt Control Switch BLateral Tilt Symbol CIndicator Arrows DLateral Tilt Switch

D
UN07JUN01

OUO6075,0001978 1924JUL012/2

25-23

H68462

101801

PN=91

H68461

UN06JUN01

Warning Devices and Monitors

Header Ground Pressure


Header Ground Pressure (Auto float) allows the operator to establish a float set point. Activation buttons 1, 2 and 3, located on the multi-function lever, can be used for selecting three different header pressures.

NOTE: If both Return to Cut and Header Ground Pressure are enabled, activation buttons 1 and 2 will activate Return to Cut. Activation button 3 will be assigned to Header Ground Pressure.
Operation: Header Ground Pressure mode can be activated only when: 1. 2. 3. 4. The engine is running The road safety switch is in the field position Header Ground Pressure mode is enabled The header engage switch is engaged
1Activation Button 2Activation Button 3Activation Button

Continued on next page

OUO6075,00018DB 1928JUN011/2

25-24

PN=92

H68443
101801

UN07JUN01

H68463

UN06JUN01

Warning Devices and Monitors


The system is enabled by pressing switch (A) on the corner post display unit. Symbol (B) will appear on the display. Activate the system by pressing one of the activation buttons 1,2 or 3 on the multi-function lever. Arrows (C) on each side of the symbol indicate that the system is active. The number (D) in the lower left corner of the display indicates which activation button was pushed. To change the pressure setpoint (E) of any of the activation buttons, press the desired activation buttons and adjust the pressure using the ground pressure control knob (F) to move the pressure setpoint and to reduce the header ground pressure (raise header) or to increase the header ground pressure (lower header). Turning the knob towards the (+) symbol will reduce the header ground pressure (raise the header). Turning the knob towards the (-) symbol will increase the header ground pressure (lower the header). Bar graph (G) and number display (H) show the ground pressure. Units are kPa for metric system and psi for English system Manually raising the header with switch (I) on the multi-function lever will turn off the Header Ground Pressure function. Pressing any of the activation buttons will re-activate the system and the header will move to the selected pressure. The system can be disabled by pressing switch (A).
AHeader Ground Pressure Switch BHeader Ground Pressure Symbol CArrows DDisplay Number EPressure Setpoint FPressure Control Knob GBar Graph HNumber (in bar) IHeader Raise/Lower Switch
UN07JUN01

OUO6075,00018DB 1928JUN012/2

25-25

PN=93

H68456
101801

H68464

UN06JUN01

Warning Devices and Monitors

Reel Position Resume


Reel Position Resume allows the operator to select the position of the reel. Activation buttons 1, 2 and 3 located on the multi-function lever are used for selecting three different reel positions. Operation: Reel Position Resume system can be activated only when: 1. 2. 3. 4. 5. The engine is running. The road safety switch is in the field position. Reel Position Resume mode is enabled. The header engage switch is engaged. Return to Cut, Stubble Height Control or Header Ground Pressure function activated
UN06JUN01

Use switch (A) to obtain desired reel fore-and-aft position and to obtain the reel height position. Press and hold one of the activation buttons 1,2 or 3 on the multi-function lever more than 2 seconds to memorize the reel position. Manually moving the reel with switch (A) on the multi-function lever will turn off the reel position resume function. Pressing the corresponding activation button will re-activate the system and the reel will move to the selected position. When harvesting conditions are such that more than one reel position is required, e.g., one position for down crop and one position for standing crop, the operator can store a reel position for each resume button and move from one reel position to the other by pushing and releasing resume buttons.
AReel Lift and Reel Fore/Aft Switch 1Activation Button 2Activation Button 3Activation Button

OUO6075,00018DC 1928JUN011/1

25-26

PN=94

H68466
101801

UN07JUN01

H68465

Warning Devices and Monitors

VISIONTRAKDisplay Module
The VISIONTRAK display module allows the operator to do desired calibrations and setups for the grain loss monitor. The module will display total grain loss as well as shoe and separator loss individually. The system will also display tailings volume and adjustable deck plate position (if equipped with this option).
AAdjustable Deck Plate Position (Optional) BTailings Volume Display Icon CShoe Icon DShoe Loss Display ETotal Loss Display FControl Keys GDeck Plate Position (Optional) HChopper Deflector Vane Position IAdjustable Chopper Deflector Vane Position JTailings Volume Display KSeed Size LSeparator Icon MSeparator Loss Display

VISIONTRAK is a trademark of Deere & Company

OUO6075,00018DE 1928JUN011/1

VISIONTRAK Display Control Switches


ACalibration Switch BUp Arrow Switch CSeed Size Switch DDown Arrow Switch

OUO6075,000026E 1908DEC001/1

25-27

101801

PN=95

ZX018673

UN12NOV99

ZX018672

UN26NOV99

Warning Devices and Monitors

Calibration Switch
Calibration switch is used to calibrate total grain loss based on the current loss levels of each sensor.
UN04NOV99

OUO6075,00013CC 1902FEB011/1

Up/Down Arrow Switch


NOTE: Using this switch in the diagnostics/calibration mode will not change any calibrations for the VISIONTRAK monitor.
Pressing and releasing either arrow switch will cause the unit to blank the deck plate icon (if equipped) and display the current calibration setting for the grain loss monitor.
UN04NOV99

OUO6075,000026F 1908DEC001/1

Seed Size Switch


Pressing and releasing the seed size switch will increment the seed size by one. When the largest size is reached the next increment will result in the smallest seed size being shown. The last seed size displayed will be kept in the memory when the combine is turned off. When the combine is powered up the last seed size will be displayed.

OUO6075,00018DF 1928JUN011/1

25-28

101801

PN=96

ZX018679

UN04NOV99

ZX018676

UN04NOV99

ZX018675

ZX018674

Warning Devices and Monitors

Adjustable Deck Plate Position (Optional)


NOTE: To calibrate adjustable deck plates, (see Calibration Procedures section).
The reel fore/aft switch (A) on the multi-function lever allows the operator to open and close the adjustable deck plates on corn heads (if equipped). The deck plates can be moved only when:
UN07JUN01

Engine is running, Road safety switch (B) is in the field position Pressing the reel forward switch (C) opens the deck plates and pressing the reel aft switch (D) closes the deck plates. The deck plate position icon (E) and plate opening (F) (a decimal value between 0 and 9) will be displayed in the upper left-hand side of the display. Zero will be displayed with the deck plates at minimum position and 9 will be displayed with the deck plates opened to maximum position.
AReel Fore/Aft Switch BRoad Safety Switch CReel Forward Switch DReel Aft Switch EDeck Plate Position Icon FDeck Plate Opening

OUO6075,00018E0 1928JUN011/1

25-29

101801

PN=97

ZX018715

UN04NOV99

H68472

Warning Devices and Monitors

Tailings Sensor Display


The tailings volume is displayed as a percentage of totally full in a horizontal bar graph (A) located in the upper portion of the display. The tailings icon (B) is located to the left of the bar graph. Tailing volume is defined as the total amount of material (grain and material other than grain) moving through the tailings elevator. For the tailings sensor display to operate: Engine must be running. Road safety switch (C) must be in field position. Header switch (D) and separator switch (E) must be engaged.
AHorizontal Bar Graph BTailings Icon CRoad Safety Switch DHeader Switch ESeparator Switch

OUO6075,0000334 1908JAN011/1

25-30

PN=98

H68473
101801

UN07JUN01

ZX018716

UN04NOV99

Warning Devices and Monitors

Tailings Sensor Display Operational Check


NOTE: A wrong seed size setting will cause inaccurate display of tailings volume.
Check for acceptable loss. Check the tailings sensor display for the location of the bar graph (A). The bar graph is a visual guide which the operator can refer to periodically for an increase or decrease in tailings volume. If the bar graph begins to show an increase in volume, the operator can slow the combine speed and see if the bar graph goes back into the acceptable loss range.
ABar Graph

OUO6075,00002D5 1915DEC001/3

If bar graph (A) does not go back into the acceptable loss range after slowing down the combine, disengage the header switch. The bar graph should zero (nothing shown on the bar graph) after running at high idle for 2 minutes with separator engaged and header disengaged. Engage the header switch and the bar graph should go back into the acceptable range.
ABar Graph

Continued on next page

OUO6075,00002D5 1915DEC002/3
101801

25-31

PN=99

ZX018684

UN04NOV99

ZX018682

UN04NOV99

Warning Devices and Monitors


If the tailings sensor display consistently reads full scale (all bars lit) when not harvesting crop or is empty (0 bars lit) when harvesting crop, it may indicate that the lens is coated with material or the seal under the lens has allowed dust to enter: 1. Remove the tailings sensors (A). Inspect and clean the lenses if needed. 2. If the lenses are clean remove the lens and check for dust under the lens. If dust is found, completely clean the area and reassemble the lens onto the unit making sure the gasket is sealing. 3. Replace sensor and test the system.
ASensors
UN26NOV99

If the display continues to read full scale or empty, contact your John Deere dealer.

OUO6075,00002D5 1915DEC003/3

VISIONTRAK Performance Monitor


The VISIONTRAK system allows the operator to monitor grain loss of the cleaning shoe and separator. The system is adjustable to monitor crops of different sizes under varying conditions. The grain loss information will be displayed in the lower portion of the display by the three bar graphs (A).
ABar Graphs

OUO6075,0000271 1908DEC001/1

25-32

101801

PN=100

ZX018701

UN04NOV99

ZX018777

Warning Devices and Monitors

Shoe Loss
Shoe loss will be shown by two adjacent vertical bar graphs (A) located to the left of the display area. A shoe icon (B) is displayed above the bar graphs.
AVertical Bar Graph BShoe Icon

AG,OUZXMAY,140 1917OCT991/1

Separator Loss
Separator loss will be shown by two adjacent vertical bar graphs (A) located to the right of the display area. A separator icon (B) is displayed above the bar graphs.
AVertical Bar Graph BSeparator Icon

AG,OUZXMAY,141 1917OCT991/1

25-33

101801

PN=101

ZX018687

UN04NOV99

ZX018686

UN04NOV99

Warning Devices and Monitors

Total Loss
Total loss will be shown on a vertical bar graph (A) located in the center of the lower portion of the display. When the graph is between the two horizontal lines (B) the loss is at the level for which it was calibrated. A summation symbol (C) is displayed above the bar graph.
AVertical Bar Graph BHorizontal Lines CSummation Symbol

AG,OUZXMAY,142 1917OCT991/1

Preliminary Adjustments on Combine


Before making any adjustments on the VISIONTRAK Performance Monitor, adjust the combine so that it is operating at peak efficiency. The adjustments must correspond to the relevant crop and field conditions. For details, see Crop Settings and Seed Loss Charts Section.

OUO6075,0000272 1908DEC001/1

25-34

101801

PN=102

H52739

UN05MAR99

ZX018688

UN04NOV99

Warning Devices and Monitors

VISIONTRAK Performance Monitor (General Information)


The system is active whenever the header is engaged and in some diagnostic modes. Determine the grain size of the crop being harvested. The seed size may be selected by pushing the seed size switch (B). The seed size indicator (G) is located in the center VISIONTRAK Performance Monitor. It will change to show the selected seed size. The VISIONTRAK Performance Monitor checks grain loss by measuring a representative sample of losses over the cleaning shoe sensors and through the separator. A change in loss rate is indicated by the activity indicators. The four narrow activity indicators (D), (E), (I) and (J) show the activity on each of the four sensors. The system can be set to two modes. The standard mode averages the shoe sensors and averages the separator sensors. The optional mode shows the activity of each individual sensor. These activity indicators will not change sensitivity with a change in the system calibration. The wide total activity indicator (H) shows the total of the seed hits from the four sensors. This total can be adjusted so that normal performance will show the bar mid point. To set the VISIONTRAK, tune the combines performance to an acceptable loss level. While operating at the desired combine performance, push the calibrate switch (C). This will enter the current operating characteristics into memory and center the center bar graph (total activity indicator) display. The calibration reference number will also be shown (F) for future use. The system is now set up to help the operator maintain the combine performance. The monitor can also be used to detect plugged or closed sieves and chaffers. A sudden upward movement of the bar graphs when field conditions are unchanged can indicate that sieve or chaffer are plugged or closed. When this happens, stop the combine and correct the problem.

AVISIONTRAK Performance Monitor BSeed Size Switch CCalibrate Switch DShoe Activity Indicator EShoe Activity Indicator FCalibration Reference Number GSeed Size Indicator HTotal Activity Indicator ISeparator Activity Indicator JSeparator Activity Indicator

OUO6075,0001523 1921FEB011/1

25-35

101801

PN=103

ZX018717

UN26NOV99

Warning Devices and Monitors

Operating VISIONTRAK Performance Monitor


The system will operate only when the: Engine is running. Road safety switch is in the field position. Header switch is engaged Separator switch is engaged.

1. Press switch (A) for the closest grain size. Seed size: Small size Flax Grass Millet Mustard Oats Rape Rice Rye

Middle size Guar Popcorn Safflower Sorghum Wheat Barley

ASwitch

Large size Corn Edible Beans Peas Soybeans Sunflowers

2. Adjust combine and header to an acceptable loss level for the particular crop and condition. Ignore the center bar graph at this time.

Continued on next page

OUO6075,0000279 1908DEC001/4
101801

25-36

PN=104

ZX018718

UN04NOV99

Warning Devices and Monitors


NOTE: Shoe and separator activity indicators (outside bar graphs) can be used to help determine which area has to be adjusted.
3. Operate the combine at the acceptable loss level.

OUO6075,0000279 1908DEC002/4

4. Pressing and releasing the calibration switch (B) will place the total loss display in the center of the acceptable area on the display (C). The bar graph shows the combine is operating at the total loss level that was acceptable to the operator in step 3. The center bar graph is now a visual guide the operator can refer to periodically to know when there is an increase or decrease in the total loss amount.
BCalibration Switch CDisplay

Continued on next page

OUO6075,0000279 1908DEC003/4

25-37

101801

PN=105

ZX018719

UN04NOV99

Warning Devices and Monitors


5. If the bar graph moves downward (A), the combine is not operating at maximum productivity. Increase ground speed slightly to bring the bar graph back into the middle of the acceptable area on the display. 6. If the bar graph moves upward (B), the combine is either incorrectly adjusted for an acceptable loss level or is moving at too fast a ground speed. Make combine and/or header adjustments as necessary or reduce ground speed to bring the bar graph back into the middle of the acceptable area on the display. 7. When crop conditions change during the day (straw moisture, dew, etc.), make an occasional loss check to determine if readjustment or re-calibration is necessary.
ABar Graph (downward) BBar Graph (upward)
UN01APR99

NOTE: When the combine encounters a slug the middle bar graph will fluctuate upward (for about 1520 seconds) and will return to previous reading. Ignore these fluctuations.

OUO6075,0000279 1908DEC004/4

Additional Control Switches (VISIONTRAK Monitor)


ABack Arrow Switch BDiagnostics Switch CEnter Switch DArea Counter Switch

OUO6075,000027A 1908DEC001/1

25-38

101801

PN=106

ZX018720

UN04NOV99

H52743

Warning Devices and Monitors

Back Arrow Switch


Pressing and releasing the back arrow switch will allow the operator to back out to the previous mode.
UN04NOV99

AG,OUZXMAY,132 1916OCT991/1

Diagnostics Switch
Pressing and releasing the diagnostic switch will put the monitor into the diagnostic mode.
UN04NOV99

AG,OUZXMAY,133 1916OCT991/1

Enter Switch
Pressing and releasing the enter switch allows entry of data into the memory.
UN04NOV99

AG,OUZXMAY,135 1916OCT991/1

Area Counter Switch


Pressing and releasing the area counter switch will allow the operator to display the total area on the top line of the Triple Display Tachometer.
UN04NOV99

AG,OUZXMAY,156 1930OCT991/1

25-39

101801

PN=107

ZX018721

ZX018680

ZX018678

ZX018677

Warning Devices and Monitors

Area Counter Operation


Pressing switch (A) will activate the area counter display (B) of the Triple Display Tachometer. To turn off the area counter and return to the normal tachometer display by pressing switch (A). For metric system ha for hectares will appear and for English system A for acres will appear. - Total Machine Area Counter is shown on the top line (C) along with the unit symbol (D). It accumulates area anytime the field counter accumulates area. - Field Total Area Counter is shown on the middle line (E). This counter will sum area accumulated by the Field Area Counter until this one is cleared. This counter can be cleared through quick calibration procedure (ACFt), (see Calibration Procedures section). - Field Area Counter is shown on the lower line (F). This counter accumulates area anytime a valid header is installed, header width is greater than zero and machine is in harvesting mode. This counter can be cleared through quick calibration procedure (ACFt), (see Calibration Procedures section). The currently active area counter is selected by pressing switch (G) and indicated by arrow (H). Area will only be accumulated and shown for the currently active area and the total area. The area counting shall start and stop based upon the machine harvesting status message received from the header controller. How to set the machine harvesting threshold, (see Calibration Procedures section.
AArea Counter Switch BArea Counter Display CUpper Line DSymbols EMiddle Line FLower Line GSwitch HArrow
UN17NOV99

Continued on next page

OUO6075,0001524 1921FEB011/2
101801

25-40

PN=108

ZX018988

UN26NOV99

ZX018987

Warning Devices and Monitors


The area will be displayed to the nearest 1/10 of a unit (XXX.X) until a value of 999 units is reached. Then the display will only show area to the nearest whole units (XXXX). If the area counter is not cleared prior to reaching 9999 then on the next accumulated unit the counter will roll over to 0 and will continue to display whole units to indicate that a number greater than 9999 exists. How to clear the area counter (using a quick calibration procedure), (see Calibration Procedures section).

OUO6075,0001524 1921FEB012/2

Triple Display Tachometer


AFuel Gauge BCoolant Temperature Gauge CUpper Line Display DMiddle Line Display ELower Line Display FControl Keys

AG,OUZXMAY,123 1916OCT991/1

25-41

101801

PN=109

ZX018667

UN15NOV99

Warning Devices and Monitors

Control Switches
AEngine Speed BCylinder Speed CConcave Clearance DUp/Down Arrows (Display Line Select) EClock Select FFan Speed GFixed Feeder House Speed HEngine Hours/Separator Hours

AG,OUZXMAY,124 1916OCT991/1

Engine Speed Switch


Pressing and releasing the engine speed switch will display the engine speed (rpm) on either line (middle or lower, depends on which line is selected) of the display.
UN04NOV99

AG,OUZXMAY,157 1930OCT991/1

Cylinder Speed Switch


Pressing and releasing the cylinder speed switch will display the cylinder speed (rpm) on either line (middle or lower, depends on which line is selected) of the display.
UN04NOV99

AG,OUZXMAY,158 1930OCT991/1

25-42

101801

PN=110

ZX018723

ZX018722

ZX018668

UN15NOV99

Warning Devices and Monitors

Concave Clearance Switch


Pressing and releasing the concave clearance switch will display the concave clearance (as a relative number) on either line (middle or lower, depends on which line is selected) of the display.

AG,OUZXMAY,159 1930OCT991/1

Up/Down Arrow Switch (Display Line Select)


Pressing and releasing the up/down arrows switch will move the display from the currently active line to the other line.
UN04NOV99

AG,OUZXMAY,160 1930OCT991/1

Clock Select Switch


Pressing clock switch will display the time on the display.

OUO6075,00018E1 1928JUN011/1

Fan Speed Switch


Pressing and releasing the fan speed switch will display the cylinder fan (rpm) on either line (middle or lower, depends on which line is selected) of the display.
UN04NOV99

AG,OUZXMAY,161 1930OCT991/1

25-43

101801

PN=111

ZX018726

ZX018776

UN26NOV99

NOTE: Reset the digital clock if the battery was disconnected or the battery switch was moved to OFF position. (see Calibration Procedures section).

ZX018725

ZX018724

UN04NOV99

Warning Devices and Monitors

Fixed Speed Feeder House Switch


Pressing and releasing the fixed speed feeder house switch will display the fixed feeder house speed (rpm) on either line (middle or lower, depends on which line is selected) of the display.

AG,OUZXMAY,162 1930OCT991/1

Engine Hours/Separator Hours Switch


Pressing and releasing the engine hours/separator hours switch will display the engine or separator hours along with the appropriate symbol on the middle line of display.
UN04NOV99

AG,OUZXMAY,163 1930OCT991/1

25-44

101801

PN=112

ZX018728

ZX018727

UN04NOV99

Warning Devices and Monitors

Fuel Gauge
With key on, fuel gauge will move to right showing amount of fuel in tank. When only 11% of fuel is left in tank, the low fuel light will come on and the buzzer will sound four times every five minutes until fuel is added.

NOTE: Fuel tank capacity is 700 L (185 U.S. gal)

OUO6075,00018E2 1928JUN011/1

Coolant Temperature Gauge


The engine coolant gauge displays the temperature of the engine.
UN15SEP00

Three or four arrows are displayed for normal operating temperature. IMPORTANT: If the red ENG TEMPERATURE light on warning display panel comes on and the buzzer sounds, stop engine and check problem immediately.

OUZXMAG,0000784 1906SEP001/1

25-45

101801

PN=113

ZX022454

ZX018669

UN12NOV99

Warning Devices and Monitors

Digital Display Lines


At power up, along with the appropriate symbol the upper line (A) will display the ground speed (km/h or MPH) or total area (ha for hectares or A for acres) when the area counter switch is pressed. Field Total Area Counter is shown on the middle line of the display. Field Area Counter is shown on the lower line of the display. The middle line (B) and lower line (C) can display the same data. The operator can select any of the following data to be displayed on either line (middle or lower) of the display. Engine Speed (RPM) Threshing Cylinder Speed (RPM) Fan Speed (RPM) Header Back shaft Speed (RPM) Concave Clearance as a relative number

To display engine and separator hours, press the hour switch (D). The engine or separator hours along with the appropriate symbol will be displayed on the middle line. The hours will remain displayed for ten seconds or until another switch is pressed which will return the display to its previous mode. The middle and lower display will always show the last information displayed when the key was turned off. Either the middle line or the lower line of the display can be changed by the operator to display any data of his choice. The line that is currently active to change, will be shown by an indicator arrow (E) at the left side of the digital display. The appropriate arrow will be displayed when the operator pushes the up/down arrow key (F). Pressing the concave clearance, cleaning fan speed or the cylinder speed switches on the armrest will cause the digital display to display that function for 10 seconds after the function switch is released.

AUpper Line BMiddle Line CLower Line DHour Switch EIndicator Arrow FUp/down Arrow Key

OUO6075,0000345 1908JAN011/1

25-46

101801

PN=114

ZX018671

UN04NOV99

Warning Devices and Monitors

Tachometer Service Information


CAUTION: To prevent injury, never lubricate or service combine, header, or engine while it is running. Engine must be off, key removed and parking brake set. Use hour meter as a guide when servicing the combine. Every 50 hours of engine operation, the characters SEU will appear on the tachometer display indicating service is needed. The service interval timer can also be reset if service is performed between 45 and 50 hours but not prior to 45 hours. IMPORTANT: The service times are for average conditions. Service more often if combine is used in extreme conditions. To clear the service indicator (SEU) (see Calibration Procedures section).

OUZXMAG,0000785 1906SEP001/1

25-47

101801

PN=115

ZX018752

UN12NOV99

Warning Devices and Monitors

Diagnostic Icon
Diagnostic icon, steady Diagnostic Icon (A) is on steady and a diagnostic trouble code is displayed on the three lines. This means a corrective action is immediately required. Do not operate combine until the problem is corrected. Diagnostic icon, flashing The diagnostic icon (A) is flashing continuously. This means a diagnostic code has been generated. Stop the combine when convenient and determine the cause.

AG,OUZXMAY,172 1901NOV991/1

25-48

101801

PN=116

ZX018757

UN12NOV99

ZX018756

UN12NOV99

Warning Devices and Monitors

Low Shaft Speed Monitor (General Information)

4/4

3/4

The low shaft speed monitor shows with lights and a buzzer when chopper, grain separator, auger conveyor, grain elevator and tailings elevator are operating less than 85 percent of their designed speed.

If all the lights come on and the buzzer sounds, start engine, engage separator and header drive switches and run engine at fast idle. If lights continue to stay on, disengage separator and header switches and idle engine. Shut off engine, set parking brake and remove key, and (see Troubleshooting section). CAUTION: Shut off engine, set parking brake and remove key before working on combine. IMPORTANT: The sensors are not adjustable.

NOTE: The electric clutch and low shaft speed monitor are both on the same circuit.
To check operation of monitor, turn key to ON (do not start engine) and engage separator and header drive switches. All lights must turn on and buzzer must sound. If they do not, (see LOW SHAFT SPEED MONITOR TROUBLESHOOTING).

OUO6075,00018E3 1928JUN011/1

25-49

101801

PN=117

H68974

UN26JUN01

Warning Devices and Monitors

Low Shaft Speed Monitor Troubleshooting


A yellow light comes on and the buzzer sounds whenever any of the five functions is running below proper speed. The separator and header drive switches must be on to turn on this system. CAUTION: Shut off engine, set parking brake and remove key. When the buzzer sounds, check for: Plugged chopper, cylinder or augers, or a broken belt. Then check for: Broken or disconnected sensor wires. Damaged sensor. Loose sensor actuator on shaft collar. If the light and buzzer still stay on after checking those items, short both sensor wires to ground. If the light and buzzer then go out, replace that sensor. If, after replacing the sensor, the light and buzzer still stay on, see your John Deere dealer.

OUO6075,00014C2 1921FEB011/1

25-50

101801

PN=118

Calibration Procedures
When to Calibrate
The following calibration procedures must be performed before first use or when replacing any of the sensors. Concave Sensor Zero Calibration - conc Header Calibration - hdr HEADERTRAK Angle Sensor Calibration - tilt (Optional) Hydraulic Adjustable Deck Plate (optional) Sensor Calibration - dEc

NOTE: The condition causing the error must be corrected before the calibration can be continued.
If any errors occur during the calibration procedures, error codes will be displayed on the triple display tachometer.

OUO6075,00018E4 1928JUN011/1

How Diagnostic Address Information is Displayed


The diagnostic address information is listed in chart form on the following pages. For each address, there is a description of the information available. The description includes details about how the information is presented. They are listed by function, so all addresses that refer to the same type of information are listed together. In some systems, the same bit of information can be found in two or more addresses. The chart uses characters to describe how the information is displayed: n - a numerical value 1 - a 1 or a 0 will be shown. This indicates ON or OFF as shown in the address description x - the information in this character location is not important. _ - Blank spot. No character displayed

AG,OUZXMAY,215 1913NOV991/1

30-1

101801

PN=119

Calibration Procedures

Diagnostic Trouble Codes


Diagnostic Trouble Code Priorities Each Diagnostic Trouble Code (DTC) has a priority. The priority of the DTC is indicated in the way the DTC is displayed to the operator: Priority 1 - The Cornerpost Display 1 will stop normal function and the DTC will be displayed. This indicates a problem that requires the combine be stopped, the engine turned off immediately and the problem corrected. The Cornerpost Display 1 will show the DTC until the problem is resolved. Priority 2 - The Cornerpost Display 1 Diagnostic Indicator comes on. This indicates a problem that should be checked immediately Priority 3 - DTCs will be stored, but it is not indicated to the operator. Accessing Diagnostic Trouble Codes Prepare Combine: Turn the key switch to the run position.

OUO6075,0001977 1924JUL011/25

Press the diagnostic switch. dIA will appear on the Cornerpost Display 1.

Continued on next page

OUO6075,0001977 1924JUL012/25

30-2

101801

PN=120

ZX018729

UN15NOV99

Calibration Procedures
Press the up or down arrow switch to obtain the desired address. For example A00 appears on the Cornerpost Display 1.

OUO6075,0001977 1924JUL013/25

Press the enter switch.

OUO6075,0001977 1924JUL014/25

Press the up arrow switch once. If diagnostic trouble codes are available A00 and codE will appear on Cornerpost Display 1. If no DTC is available A00 and nonE will appear on Cornerpost Display 1.

Continued on next page

OUO6075,0001977 1924JUL015/25
101801

30-3

PN=121

ZX019003

UN15NOV99

ZX019002

UN15NOV99

ZX018990

UN15NOV99

ZX019001

UN15NOV99

Calibration Procedures
To read and record diagnostic trouble codes press the enter switch.

OUO6075,0001977 1924JUL016/25

Press the up or down arrow switch to scroll through the diagnostic trouble codes. Record each control unit name Record each suspected parameter number Record each failure mode identifier

OUO6075,0001977 1924JUL017/25

After all codes have been displayed, there is an option to clear these codes. Scroll to end of code list until CLr? is displayed.
UN15NOV99

OUO6075,0001977 1924JUL018/25

Press the enter switch to clear codes. A00 and donE will appear on Cornerpost Display 1.

Continued on next page

OUO6075,0001977 1924JUL019/25
101801

30-4

PN=122

ZX019006

UN15NOV99

ZX019005

ZX019004

UN15NOV99

ZX018990

UN15NOV99

Calibration Procedures
NOTE: Priority 1 codes cannot be cleared until the problem is solved.
Press back arrow switch three times to return to normal operation.
UN15NOV99

Continued on next page

OUO6075,0001977 1924JUL0110/25

30-5

101801

PN=123

ZX019007

Calibration Procedures

DTC Controller List A00


C00
C03
E00
E01
E02 E03
Display & Clear DTC's

Diagnostics Menu - _dIA


ALL
CAL

E04

A00
C00
C03
E00
E01
E02 E03 E04

Quick Cal Menu conc


hdr

Concave Position Sensor Calibration

tilt
dec

Header Calibration

Contour Master Angle Sensor Calibration

Deck Plate Position Sensor Calibration


Diagnostic Address List 000
001
002
----255
Machine Setting Address
1902AUG01
101801

Up & Down Arrow to change address CAL to change digit Enter to set

Continued on next page

OUO6075,0001977 1924JUL0111/25

30-6

PN=124

H69515

Calibration Procedures
A00 - Engine Control Unit Diagnostic Trouble Codes
Control Unit
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00

SPN
91
94
94
94
94
94
94
94
94
94
94
97
97
97
100
100
105
105

FMI
09
01
01
03
03
04
04
10
13
17
18
03
04
31
01
04
00
03

Pri.
3
1
1
2
1
2
1
2
1
2
2
2
2
2
1
2
1
2

Description
Throttle input not valid or not received
Fuel pressure too low - less than 80kPa / 11.6 PSI (9540)
Fuel pressure too low - less than 300 kPa / 44 PSI (9880 STS)
Fuel Pressure Sensor (cc# 131) voltage out of range high (9880 STS)
Fuel Pressure Sensor (cc# 131) voltage out of range high - greater than 4 VDC (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Fuel Pressure Sensor (cc# 131) voltage out of range low (9880 STS)
Fuel Pressure Sensor (cc# 131) voltage out of range low. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
The rail pressure drops too fast when the engine is motoring and the high pressure pump is off. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Fuel Pressure Sensor reading is incorrect. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
During starting, rail pressure is not developed after a short time cranking. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Fuel pressure too low - less than 100 kPa / 14.7 PSI at low idle (9540)
Water in Fuel Sensor (cc# 136) voltage out of range high (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Water in Fuel Sensor (cc# 136) voltage out of range low (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Water is detected in fuel. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Oil Pressure Sensor is open after engine RPM is above cranking speed (9550, 9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Oil Pressure Sensor is closed when engine is not running (9550, 9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine Manifold Air Temperature above 100C / 212F. (9540))
Engine Manifold Air Temperature Sensor voltage is out of range high. The device or wiring is faulty. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine Manifold Air Temperature Sensor voltage is out of range low (less than 0.1 VDC). The device or wiring is faulty. (9540, 9550)
Engine Manifold Air Temperature Sensor voltage is out of range low. The device or wiring is faulty. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine Manifold Air temperature above 88C / 190F (moderately severe level). Maximum power level is derated. Power boost is disabled. (9550, 9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Air Filter Restricted Switch indicates a plugged air filter. (9550, 9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)

A00
A00

105
105

04
04

2
2

A00

105

16

A00

107

00

Continued on next page

OUO6075,0001977 1924JUL0112/25
101801

30-7

PN=125

Calibration Procedures
Control Unit
A00

SPN
110

FMI
00

Pri.
1

Description
Engine coolant temperature above 115C / 240F (most severe level). Maximum power level is derated. Power boost is disabled. (9550, 9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Engine Coolant Temperature Sensor voltage is out of range high (greater than 4.975 VDC). The device or wiring is faulty. (9540)
Engine Coolant Temperature Sensor voltage is out of range high. The device or wiring is faulty. (9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine Coolant Temperature Sensor voltage is out of range low (less than 0.05 VDC). The device or wiring is faulty. (9540)
Engine Coolant Temperature Sensor voltage is out of range low. The device or wiring is faulty. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine coolant temperature above 100C / 212F. Maximum power level is derated. Power boost is disabled. (9540)
Engine coolant temperature above 110C / 230F. Maximum power level is derated. Power boost is disabled. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Coolant level low. Engine coolant temperature above 125C / 257F. Maximum power level is derated. Power boost is disabled. (9550, 9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Controller not powered down properly. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine fuel temperature is too high (greater than 75C / 167F). Injector pump may be damaged because hot fuel loses its lubrication properties. (9540)
Engine Fuel Temperature Sensor voltage is out of range high. The device or wiring is faulty. Injector pump may be damaged because hot fuel loses its lubrication properties. (9550, 9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine Fuel Temperature Sensor voltage is out of range low. The device or wiring is faulty. Injector pump may be damaged because hot fuel loses its lubrication properties. (9550, 9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine fuel temperature above normal range (greater than 65C / 149F). Maximum power level and power boost are derated. (9540)
Engine fuel temperature above normal range (greater than 65C / 149F). Maximum power level and power boost are derated. (9550, 9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Engine fuel temperature above normal range (greater than 73C / 163F). Maximum power level and power boost are derated. (9540)
Engine Fuel Temperature Sensor is out of range. Maximum power level and power boost are derated. (9540)
Low fuel pressure (9540)
Engine over-speed (greater than 2800 RPM). (9540)
Engine speed too high (greater than 2800 RPM). Engine Control Unit reduce fuel flow until speed is below 2200 RPM (9540)
The injector driver has detected a short to battery in the injector wiring. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
The injector driver has detected a short to ground in the injector wiring. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
All injector currents are out of specification. The injector pull-in current is too low or the injector hold-in current is incorrect. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)

A00
A00
A00
A00
A00
A00
A00

110
110
110
110
110
110
111

03
03
04
04
16
16
01

2
2
2
2
2
2
1

A00
A00
A00

158
174
174

17
00
03

2
2
2

A00

174

04

A00
A00

174
174

15
16

2
2

A00
A00
A00
A00
A00
A00
A00
A00

174
174
189
190
190
611
611
627

16
31
00
00
16
03
04
01

1
2
3
1
3
1
1
2

Continued on next page

OUO6075,0001977 1924JUL0113/25
101801

30-8

PN=126

Calibration Procedures
Control Unit
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00

SPN
627
629
632
632
636
636
636
637
637
637
637
651
651
651
652
652
652
653
653
653
654
654
654
655

FMI
04
19
02
05
02
08
10
02
07
08
10
05
06
07
05
06
07
05
06
07
05
06
07
05

Pri.
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

Description
Engine Control Unit Power (cc# 042) missing at Engine Control Unit while Electronic Power (cc# 021) is on. (9540)
Engine Control Unit not receiving messages from Pump. (9540)
Fuel shutoff error condition detected. (9540)
The Engine Control Unit does not detect a change in engine speed after the Key Switch is turned off. Fuel shutoff not functioning correctly. (9540)
Electrical noise detected on Event Sensor + (cc# 172) and/or Event Sensor - (cc# 173) (9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Event Sensor signal is missing (9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Event Sensor signal has incorrect pulse pattern (9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Electrical noise detected on Event Sensor + (cc# 174) and/or Event Sensor - (cc# 175) (9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Position relationship between Engine Speed Sensor and Event Sensor not correct (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine Speed Sensor signal is missing (9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine Speed Sensor signal has incorrect pulse pattern (9650, 9650CTS 9650STS, 9750STS, 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The current to Injector #1 is less than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The current to Injector #1 increases too rapidly. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The fuel flow to cylinder #1 is lower than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
The current to Injector #2 is less than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The current to Injector #2 increases too rapidly. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The fuel flow to cylinder #2 is lower than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
The current to Injector #3 is less than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The current to Injector #3 increases too rapidly. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The fuel flow to cylinder #3 is lower than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
The current to Injector #4 is less than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The current to Injector #4 increases too rapidly. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The fuel flow to cylinder #4 is lower than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
The current to Injector #5 is less than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)

Continued on next page

OUO6075,0001977 1924JUL0114/25
101801

30-9

PN=127

Calibration Procedures
Control Unit
A00
A00
A00
A00
A00
A00
A00
A00

SPN
655
655
656
656
656
729
729
1076

FMI
06
07
05
06
07
03
05
02

Pri.
2
2
2
2
2
2
2
2

Description
The current to Injector #5 increases too rapidly. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The fuel flow to cylinder #5 is lower than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
The current to Injector #6 is less than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The current to Injector #6 increases too rapidly. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
The fuel flow to cylinder #6 is lower than expected. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Inlet Air Heater Relay Output (cc# 189) is high when Engine Control Unit is not energizing the Inlet Air Heater Relay. (9540)
Inlet Air Heater Relay Output (cc# 189) is low when Engine Control Unit is energizing the Inlet Air Heater Relay. (9540)
The High Pressure Solenoid within the pump is continuously energized, the Pump Control Unit is unable to detect closure of the High Pressure Solenoid Valve or the internal pump speed sensor is broken. (9540)
The High Pressure Solenoid Valve is closed when the Engine Control Unit is commanding the Pump Control Unit to stop delivering fuel. (9540)
The Pump Control Unit senses an abnormal voltage on Pump Power (cc# 061). (9540)
The Pump Control Unit detects an error during a self test. (9540)
The Pump Control Unit is not receiving any ECU/CAN messages while detecting a signal on Crank Speed Out (cc# 187). (9540)
Injection Pump initiated engine protection due to Diagnostic Trouble Code 174.31, 1076.02, 1077.12, 1078.07 or 1078.31. Engine will derate. (9540)
The Pump Control Unit receives a crank signal from the Engine Control Unit that is moderately different than the internal timing within the Pump. Engine will be derated. (9540)
The Engine Control Unit detects a difference between the internal pump timing and engine speed. (9540)
The Pump Control Unit receives a crank signal from the Engine Control Unit that is extremely different than the internal timing within the Pump. Engine will be derated. (9540)
Sensor Supply Voltage 1 (cc# 131) too high (greater than 4.95 VDC). (9540)
Sensor Supply Voltage 1 (cc# 131) too low (less than 4.0 VDC). (9540)
Rail Pressure Sensor Power (cc# 721) voltage too high. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Rail Pressure Sensor Power (cc# 721) voltage too low. (9540)
Rail Pressure Sensor Power (cc# 721) voltage too low. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Driver detects problem in circuit to Pump Solenoid 1 Low (cc# 178). (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Rail Pressure Control is unable to match required rail pressure. It may bee too high or too low. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Pump Solenoid 1 is not delivering expected fuel flow. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Driver detects problem in circuit to Pump Solenoid 2 Low (cc# 179). (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)

A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00
A00

1077
1077
1077
1077
1077
1078
1078
1078
1079
1079
1080
1080
1080
1347
1347
1347
1348

07
11
12
19
31
07
11
31
03
04
03
04
04
05
07
10
05

2
2
2
2
1
2
2
2
2
3
1
3
1
2
2
2
2

Continued on next page

OUO6075,0001977 1924JUL0115/25
101801

30-10

PN=128

Calibration Procedures
Control Unit
A00
A00
A00

SPN
1348
1485
1569

FMI
10
02
31

Pri.
2
2
2

Description
Pump Solenoid 2 is not delivering expected fuel flow. (9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS)
Pump Power (cc# 061) is powered when Engine Control Unit is off. (9540)
Engine protection - power derated due to other faults. This code occurs in conjunction with 105.16, 110.00, 110.03, 110.04, and 110.16. (9550, 9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)
Engine Control Unit security violation. (9540, 9550, 9650, 9650CTS 9650STS, 9750STS, 9640, 9560, 9660, 9580, 9680, 9780 CTS, 9880 STS)

A00

2000

13

Continued on next page

OUO6075,0001977 1924JUL0116/25

30-11

101801

PN=129

Calibration Procedures
C00 - Armrest Control Unit Diagnostic Trouble Codes
Control Unit
C00
C00
C00
C00
C00
C00
C00

SPN
158
170
170
172
172
190
605

FMI
04
03
04
03
04
09
04

Pri.
3
3
3
3
3
3
3

Description
Control Circuit Power (cc# 023) is below 10.5 VDC.
CLIMATRAK Inlet Air Temperature Sensor voltage too high - greater than 4.8 VDC. Indicates that the sensor resistance is greater than 60K (-22F or -30C).
CLIMATRAK Inlet Air Temperature Sensor voltage too low - less than 0.1 VDC. Indicates that the sensor resistance is less than 50 (293F or 145C).
CLIMATRAK Ambient Air Temperature Sensor voltage too high - greater than 4.8 VDC. Indicates that the sensor resistance is greater than 60K (-22F or -30C).
CLIMATRAK Ambient Air Temperature Sensor voltage too low - less than 0.1 VDC. Indicates that the sensor resistance is less than 50 (293F or 145C).
CAN Bus message missing from Engine Control Unit - Engine Speed
CLIMATRAK Lo Pressure Switch (cc#914) is 12VDC. A CAN Bus message from the Left Control Unit indicates that the CLIMATRAK Hi Pressure Switch (cc#915) is 0VDC. The CLIMATRAK Hi Pressure Switch is open or there is a harness problem.
Delayed Power (cc# 006) voltage is above 16 VDC. High voltage situation must be resolved.
Delayed Power (cc# 006) is below 10.5 VDC.
Controller cannot exit boot block program. Reprogram controller with SERVICE ADVISOR or replace.
Controller failed EEPROM test at power-up. Replace Armrest Control Unit if condition persists.
CAN Bus messages are not being transmitted or received correctly. Possible effects are none, slow response, or machine down.
CAN Bus message from Left Control Unit indicates that CLIMATRAK Clutch Signal (cc# 913) is 12VDC. CLIMATRAK Lo Pressure Switch (cc# 914) is 0VDC. The CLIMATRAK Lo Pressure Switch is open or there is a harness problem.
Backshaft speed unknown. Damage could occur to feederhouse if direction is changed while feederhouse is turning. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
The header engage output transistor detects an open, short, over voltage, or over temperature condition. The Armrest Control Unit will disengage the header. The fault condition must be removed before the header can be engaged.
The separator engage output transistor detects an open, short, over voltage, or over temperature condition. The Armrest Control Unit will disengage the separator. The fault condition must be removed before the separator can be engaged.
The Separator Engage fault detection circuit indicates a failure. This is an important disengagement override system. Replace the Armrest Control Unit if condition persists.
The Seat Switch has been closed continuously for 6 hours. The switch or the wiring harness is shorted. The header will not disengage when the operator has left the seat. This must be corrected.
HEADERTRAK Sensitivity Adjust voltage is too high - greater than 4.5 VDC. The device or wiring is faulty. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
HEADERTRAK Sensitivity Adjust voltage is too low - less than 0.5 VDC. The device or wiring is faulty. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
HEADERTRAK Rate Adjust voltage is too high - greater than 4.5 VDC. The device or wiring is faulty. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)

C00
C00
C00
C00
C00
C00

627
627
628
630
639
875

03
04
12
11
19
04

1
3
1
1
3
3

C00
C00

1490
1498

08
11

2
3

C00

1499

11

C00
C00

1499
1504

12
11

2
1

C00
C00
C00

1505
1505
1506

03
04
03

3
3
3

Continued on next page

OUO6075,0001977 1924JUL0117/25
101801

30-12

PN=130

Calibration Procedures
Control Unit
C00
C00
C00
C00
C00
C00
C00
C00
C00
C00
C00
C00

SPN
1506
1547
1547
1548
1548
1549
200011
200011
200017
200018
200201
200202

FMI
04
03
04
03
04
07
03
04
09
09
11
11

Pri.
3
3
3
3
3
3
3
3
3
3
3
3

Description
HEADERTRAK Rate Adjust voltage is too low - less than 0.5 VDC. The device or wiring is faulty. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
CLIMATRAK Core Temperature Sensor voltage too high - greater than 4.47 VDC. Indicates that the sensor resistance is greater than 101K (-4F or -20C).
CLIMATRAK Core Temperature Sensor voltage too low - less than 0.1 VDC. Indicates that the sensor resistance is less than 52 (356F or 180C).
CLIMATRAK Outlet Air Temperature Sensor voltage too high - greater than 4.8 VDC. Indicates that the sensor resistance is greater than 60K (-22F or -30C).
CLIMATRAK Outlet Air Temperature Sensor voltage too low - less than 0.1 VDC. Indicates that the sensor resistance is less than 50 (293F or 145C).
CLIMATRAK Water Valve position is greater than 30% different than the commanded position.
CLIMATRAK Solar Sensor voltage is too high - greater than 4.8 VDC. The device or wiring is faulty.
CLIMATRAK Solar Sensor voltage is too low - less than 1.5 VDC. The device or wiring is faulty.
CAN Bus message(s) missing from Cornerpost Control Unit.
CAN Bus message(s) missing from Left Control Unit.
Separator Engage Switch inputs are incorrect.
Header Engage Switch inputs are incorrect.

Continued on next page

OUO6075,0001977 1924JUL0118/25

30-13

101801

PN=131

Calibration Procedures
C03 - Cornerpost Control Unit Diagnostic Trouble Codes
Control Unit
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03
C03

SPN
96
110
110
110
110
111
190
190
627
628
630
639
1079
1079
1486
1486
1487
1487
1492

FMI
09
00
03
04
09
01
00
09
03
12
11
19
03
04
03
04
03
04
08

Pri.
3
3
3
3
3
1
1
3
3
1
1
3
3
3
3
3
3
3
3

Description
CAN Bus message missing from Right Control Unit - Fuel Level.
Engine Coolant Temperature is too high - greater than 110C. (9450)
Engine Coolant Temperature Sensor voltage is too high - greater than 4.9 VDC. The device or wiring is faulty. (9450)
Engine Coolant Temperature Sensor voltage is too low - less than 0.1 VDC. The device or wiring is faulty. (9450)
CAN Bus message missing from Engine Control Unit - Engine Coolant Temperature
Coolant Level low. Engine Coolant Temperature above 125 C. (9450)
Engine Speed above normal operation range. (9450)
CAN Bus message missing from Engine Control Unit - Engine Speed
Delayed Power (cc# 006) voltage out of range high - greater than 16 VDC.
Controller cannot exit boot block program. Reprogram controller with SERVICE ADVISOR or replace.
EEPROM failed test at power up. Replace Cornerpost Control Unit if condition persists.
CAN Bus messages are not being transmitted or received correctly. Possible effects are none, slow response, or machine down.
Concave Position Sensor supply voltage high - greater than 5.5 VDC.
Concave Position Sensor supply voltage low - less than 4.5 VDC.
Concave Position Sensor voltage is too high - greater than 4.5 VDC. The device or wiring is faulty.
Concave Position Sensor voltage is too low - less than 0.5 VDC. The device or wiring is faulty.
Dimmer voltage is too high - greater than 4.5 VDC. The device or wiring is faulty.
Dimmer voltage is too low - less than 0.5 VDC. The device or wiring is faulty.
Cab interior backlighting output transistor detects an open, short, over voltage, or over temperature condition. The Cornerpost Control Unit will turn off the backlighting. The fault condition must be removed before the backlighting can be turned on.
CAN Bus message missing from Master Tailings Sensor - Tailings Volume
A switch on Cornerpost Display Unit 1 is closed for longer than 30 Seconds.
A switch on Cornerpost Display Unit 2 is closed for longer than 30 Seconds.
A switch on Cornerpost Display Unit 3 is closed for longer than 30 Seconds.
CAN Bus message missing from Armrest Control Unit - Armrest Switch Status
CAN Bus message missing from Right Control Unit - Combine Temperatures
CAN Bus message missing from Right Control Unit - Grain Loss
CAN Bus message missing from Header Control Unit - Header Data
CLIMATRAK Temperature Setpoint Adjust voltage too high - greater than 4.5 VDC. Device or wiring is faulty.
CLIMATRAK Temperature Setpoint Adjust voltage too low - less than 0.5 VDC. Device or wiring is faulty.

C03
C03
C03
C03
C03
C03
C03
C03
C03
C03

1493
1500
1501
1502
1503
1510
1511
1515
1552
1552

09
11
11
11
09
09
09
09
03
04

3
3
3
3
3
3
3
3
3
3

Continued on next page

OUO6075,0001977 1924JUL0119/25
101801

30-14

PN=132

Calibration Procedures
Control Unit
C03
C03
C03
C03
C03
C03
C03
C03
C03

SPN
1552
1553
1553
1553
1565
1567
100100
100101
100106

FMI
13
03
04
13
09
09
09
09
13

Pri.
3
3
3
3
3
3
3
3
3

Description
CLIMATRAK Temperature Setpoint Adjust not calibrated. Refer to Diagnostic Address C03-135 for calibration.
CLIMATRAK Fan Speed Adjust voltage too high - greater than 4.5 VDC. Device or wiring is faulty.
CLIMATRAK Fan Speed Adjust voltage too low - less than 0.5 VDC. Device or wiring is faulty.
CLIMATRAK Fan Speed Adjust not calibrated. Refer to Diagnostic Address C03-134 for calibration.
CAN Bus message missing from Armrest Control Unit - Separator and Header Engage Status
CAN Bus message missing from Header Control Unit - Control Mode
CAN Bus message missing from Left Control Unit - System Data
CAN Bus message missing from Left Control Unit 2 - System Data
A switch on Cornerpost Display Unit 4 is closed for longer than 30 Seconds.

E00 - Tailings Master Sensor Diagnostic Trouble Codes


Control Unit
E00
E00
E00
E00

SPN
190
628
630
639

FMI
09
12
11
09

Pri.
3
2
2
3

Description
CAN Bus message missing from Engine Control Unit - Engine Speed
Controller cannot exit boot block program. Reprogram controller with SERVICE ADVISOR or replace.
EEPROM failed test at power up. Replace the Master Tailings Sensor if condition persists.
CAN Bus messages are not received by the Tailings Master Control Unit in a timely manner. Possible effects are none, slow response, or machine down. Other Diagnostic Trouble Codes will indicate the lost message.
CAN Bus messages are not being transmitted or received correctly. Possible effects are none, slow response, or machine down.
Tailings system failure. Cause unknown.
Tailings system calibration is out of range high (sensor detectors are receiving too little light). Recalibrate. If situation persists, possible dirty sensor or failed sensor.
Tailings system calibration is out of range low (sensor detectors are receiving too much light). Recalibrate. If situation persists, possible missing elevator paddle or failed sensor.
Stuck photo receiver detected in Master Tailings Sensor. Clean master tailings sensor. If condition persists, replace sensor.
Master Tailings Sensor failure. Cause unknown.
Stuck photo receiver detected in Slave Tailings Sensor. Clean Slave Tailings Sensor. If condition continues, replace sensor.
Slave Tailings Sensor failure. Cause unknown.
Tailings elevator paddle missing
CAN Bus message missing from Right Control Unit - Seed Size
CAN Bus message missing from Armrest Control Unit - Header and Separator Engaged

E00
E00
E00
E00
E00
E00
E00
E00
E00
E00
E00

639
1493
1493
1493
1494
1494
1495
1495
1496
1511
1565

19
11
15
17
08
11
08
11
07
09
09

3
3
3
3
3
3
3
3
3
3
3

Continued on next page

OUO6075,0001977 1924JUL0120/25
101801

30-15

PN=133

Calibration Procedures
E01 - Header Control Unit Diagnostic Trouble Codes
Control Unit
E01
E01
E01
E01
E01
E01
E01
E01

SPN
84
190
627
628
629
630
639
1079

FMI
09
09
03
12
12
11
13
03

Pri.
3
3
1
1
2
3
3
2

Description
CAN Bus message missing from Cornerpost Control Unit - Wheel Speed
CAN Bus message missing from Engine Control Unit - Engine Speed
Controller Supply voltage out of range high - greater than 16 VDC.
Controller cannot exit boot block program. Reprogram controller with SERVICE ADVISOR or replace.
Header Controller internal error.
System not calibrated (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS) or EEPROM failed test at power up. Replace the Header Control Unit if condition persists.
Multiple CAN Bus messages have not been received by the Header Control Unit in a timely manner. Possible effects are no effect, slowed response, or no response.
Height Sensor Power (cc# 481) voltage is too high - greater than 5.25VDC. Height Sensor Power is used to power the Return To Cut Sensor, Reel Fore/Aft Position Sensor, Deck Plate Position Sensor, Right HEADERTRAK Sensor, Center HEADERTRAK Sensor and Left HEADERTRAK Sensor. The voltage regulator of the Header Control Unit is bad or there is a short in the wiring.
Height Sensor Power (cc# 481) voltage is too low - less than 4.75VDC. Height Sensor Power is used to power the Return To Cut Sensor, Reel Fore/Aft Position Sensor, Deck Plate Position Sensor, Right HEADERTRAK Sensor, Center HEADERTRAK Sensor and Left HEADERTRAK Sensor. The voltage regulator of the Header Control Unit is bad or there is a short in the wiring.
Height Sensor Power 2 (cc# 471) voltage is too high - greater than 5.25VDC. Height Sensor Power 2 is used to power the HEADERTRAK Angle Sensor and the Header Raise Pressure Sensor. The voltage regulator of the Header Control Unit is bad or there is a short in the wiring.
Height Sensor Power 2 (cc# 471) voltage is too low - less than 4.75VDC. Height Sensor Power 2 is used to power the HEADERTRAK Angle Sensor and the Header Raise Pressure Sensor. The voltage regulator of the Header Control Unit is bad or there is a short in the wiring.
HEADERTRAK system not calibrated for currently attached header. Perform the calibration procedure.
HEADERTRAK - Ground Pressure system not calibrated for currently attached header. Perform the calibration procedure. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
Header Raise Pressure (cc# 706) voltage is too low - less than 0.25 VDC. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS).
Circuit codes 436, 487, 488, and 489 changed while the HEADERTRAK system was in the automatic mode. These are the header select lines that identify the type of header on the combine.
Header not connected or invalid connection. Circuit codes 436, 487, 488, and 489 are the header select lines that identify the type of header on the combine.
Cannot activate HEADERTRAK Stubble Height or HEADERTRAK Header sensors are not available.
Header raise valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Header Raise Valve until the fault condition is removed.
Header lower valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Header Lower Valve until the fault condition is removed.

E01

1079

04

E01

1080

03

E01

1080

04

E01
E01
E01
E01

1515
1516
1517
1518

13
13
04
02

2
2
2
3

E01
E01
E01

1518
1518
1519

07
14
11

3
3
2

E01

1520

11

Continued on next page

OUO6075,0001977 1924JUL0121/25
101801

30-16

PN=134

Calibration Procedures
Control Unit
E01

SPN
1521

FMI
11

Pri.
2

Description
Tilt left valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the HEADERTRAK Tilt Left Valve until the fault condition is removed.
Tilt right valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the HEADERTRAK Tilt Right Valve until the fault condition is removed.
Reel forward valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Reel Forward Valve until the fault condition is removed.
Reel Aft valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Reel Aft Valve until the fault condition is removed.
Reel Raise valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Reel Raise Valve until the fault condition is removed.
Reel Lower valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Reel Lower Valve until the fault condition is removed.
Drop Rate valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Drop Rate Valve until the fault condition is removed.
Accumulator Shutoff valve driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Accumulator Shutoff Valve until the fault condition is removed. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
Reel Speed Increase driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Reel Speed Actuator in the increase speed mode until the fault condition is removed
Reel Speed Decrease driver detects an open, short, over voltage, or over temperature condition. The Header Control Unit will not actuate the Reel Speed Actuator in the decrease speed mode until the fault condition is removed
HEADERTRAK Return to Cut Sensor (cc# 828) voltage is too high - greater than 4.5 VDC. Faulty device or wiring.
HEADERTRAK Return to Cut Sensor (cc# 828) voltage is too low - less than 0.5 VDC). Faulty device or wiring.
Left HEADERTRAK Sensor (cc# 412) voltage is too high - greater than 4.5 VDC. Faulty device or wiring.
Left HEADERTRAK Sensor (cc# 412) voltage is too low less than 0.5 VDC. Faulty device or wiring.
Right HEADERTRAK Sensor (cc# 454) voltage is too high - greater than 4.5 VDC). Faulty device or wiring.
Right HEADERTRAK Sensor (cc# 454) voltage is too low - less than 0.5 VDC). Faulty device or wiring.
Center HEADERTRAK Sensor (cc# 414) voltage is too high - greater than 4.5 VDC. Faulty device or wiring.
Center HEADERTRAK Sensor (cc# 414) voltage is too low - less than 0.5 VDC. Faulty device or wiring.
Reel Fore/Aft Position Sensor or Deck Plate Position Sensor (cc# 834) voltage too high - greater than 4.5 VDC. Faulty device or wiring. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
Reel Fore/Aft Position Sensor or Deck Plate Position Sensor (cc# 834) voltage too low - less than 0.5 VDC. Faulty device or wiring. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)

E01

1522

11

E01

1524

11

E01
E01
E01
E01
E01

1525
1526
1527
1528
1529

11
11
11
11
11

3
3
3
3
3

E01

1531

06

E01

1532

06

E01
E01
E01
E01
E01
E01
E01
E01
E01

1533
1533
1534
1534
1535
1535
1536
1536
1537

03
04
03
04
03
04
03
04
03

2
2
2
2
2
2
2
2
3

E01

1537

04

Continued on next page

OUO6075,0001977 1924JUL0122/25
101801

30-17

PN=135

Calibration Procedures
Control Unit
E01
E01
E01
E01
E01
E01

SPN
1538
1538
1539
1539
1541
1544

FMI
03
04
03
04
02
09

Pri.
3
3
3
3
2
3

Description
Reel Height Sensor (cc# 835) voltage too high - greater than 4.5 VDC. Faulty device or wiring. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
Reel Height Sensor (cc# 835) voltage too low - less than 0.5 VDC. Faulty device or wiring. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
HEADERTRAK Angle Sensor (cc# 833) voltage too high - greater than 4.5 VDC. Faulty device or wiring.
HEADERTRAK Angle Sensor (cc# 833) voltage too low - less than 0.5 VDC. Faulty device or wiring.
Reel speed unknown.
CAN Bus message missing from Armrest Control Unit - Multifunction Handle Switch Status

E02 - Right Control Unit Diagnostic Trouble Codes


Control Unit
E02
E02
E02
E02
E02
E02

SPN
96
96
627
628
630
639

FMI
03
04
03
12
11
09

Pri.
3
3
1
1
2
3

Description
Fuel Level Signal (cc# 652) voltage is too high - greater than 1.96 VDC. The device or wiring is faulty.
Fuel Level Signal (cc# 652) voltage is too low - less than 0.12 VDC. The device or wiring is faulty.
Electronic Power (cc# 021) voltage is too high - greater than 16VDC.
Controller cannot exit boot block program. Reprogram controller with SERVICE ADVISOR or replace.
EEPROM failed test on power up. Replace the Right Control Unit if condition persists.
CAN Bus messages are not received by the Right Control Unit in a timely manner. Possible effects are none, slow response, or machine down. Other Diagnostic Trouble Codes will indicate the lost message
CAN Bus messages are not being transmitted or received correctly. Possible effects are none, slow response, or machine down.
CAN Bus message missing from Armrest Control Unit - Header Engage Status
CAN Bus message missing from Cornerpost Control Unit - Machine Configuration
CAN Bus message from Cornerpost Control Unit invalid - Machine Configuration
Hydraulic Oil Temperature Sensor (cc# 775) voltage is too high - greater than 4.97 VDC. The device or wiring is faulty.
Hydraulic Oil Temperature Sensor (cc# 775) voltage is too low - less than 0.29 VDC. The device or wiring is faulty.
Main Gearcase Oil Temperature Sensor (cc# 774) voltage is too high - greater than 4.97 VDC. The device or wiring is faulty.
Main Gearcase Oil Temperature Sensor (cc# 774) voltage is too low - less than 0.29 VDC. The device or wiring is faulty.
Chopper Vane Angle Sensor voltage is too high (above 4.97 VDC). The device or wiring is faulty. (cc# 781 in models 9540, 9640, 9560, 9660, 9580, 9680, 9780 CTS or cc# 782 on model 9880 STS)
Chopper Vane Angle Sensor out of calibration. Perform the calibration procedure. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
CAN Bus message missing from Armrest Control Unit - Discrete Input Status

E02
E02
E02
E02
E02
E02
E02
E02
E02

639
1498
1500
1500
1508
1508
1509
1509
1510

19
09
09
11
03
04
03
04
03

2
3
3
3
2
2
2
2
3

E02
E02

1510
1565

13
09

3
3

Continued on next page

OUO6075,0001977 1924JUL0123/25
101801

30-18

PN=136

Calibration Procedures
E03 - Left Control Unit Diagnostic Trouble Codes
Control Unit
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03

SPN
190
627
628
630
639
876
1497
1500
1503
1515
200112

FMI
09
03
12
11
19
11
11
09
09
09
03

Pri.
3
1
1
3
3
2
3
3
3
3
2

Description
CAN Bus message(s) missing from Engine Control Unit - Engine Speed
Electronic Power (cc# 021) voltage is too high - greater than 15.5 VDC.
Controller cannot exit boot block program. Reprogram controller with SERVICE ADVISOR or replace.
EEPROM failed test on power up. Replace the Left Control Unit if condition persists.
CAN Bus messages are not being transmitted or received correctly. Possible effects are none, slow response, or machine down.
The CLIMATRAK Compressor driver detects an open, short, over voltage, or over temperature condition.
Unloading Auger Engage driver detects an open, short, over voltage, or over temperature condition. The Left Control Unit cannot engage the auger until the fault condition is removed.
CAN Bus message(s) missing from Cornerpost Control Unit - Ground Speed and/or Machine Configuration.
CAN Bus message(s) missing from Armrest Control Unit
CAN Bus message(s) missing from Header Control Unit
12VDC is detected at the output of Grain Tank Cover Fold relay (K7) of the Control Relay Board when it is not energized. Indicates possible problem with K7 or Control Power (cc# 016) short circuit to 12VDC. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
12VDC is not detected at the output of Grain Tank Cover Fold relay (K7) of the Control Relay Board when it is energized. Indicates possible problem with K7 or Control Power (cc# 016). (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
The Unloading Auger Swing In driver or the Unloading Auger Swing Out driver detects an open, short, over voltage, or over temperature condition. The Left Control Unit cannot swing the auger until the fault condition is removed.
HILLMASTER II Engage is not ON, but 12VDC is detected on the Sidehill/HillMaster Engage Signal (cc# 447) of the Left Control Unit. Possible problem with Left Control Unit or Sidehill/HillMaster Engage Signal (cc# 447) shorted to 12VDC
Sidehill/HillMaster Engage Signal (cc# 447) is not 12VDC when ON. Possible problem with Left Control Unit or Sidehill/HillMaster Engage Signal (cc# 447) wiring. When HILLMASTER is disengaged, the Diagnostic Error Code becomes a stored code.
The Combine Lower driver detects an open, short, over voltage, or over temperature condition. The Left Control Unit cannot engage Combine Lower until the fault condition is removed.
The Left Brake Light driver detects an open, short, over voltage, or over temperature condition. Only active in the ROAD mode.
The Right Brake Light driver detects an open, short, over voltage, or over temperature condition. Only active in the ROAD mode.
The Left Marker Light driver detects an open, short, over voltage, or over temperature condition. Only active in the ROAD mode.
The Right Marker Light driver detects an open, short, over voltage, or over temperature condition. Only active in the ROAD mode.
The Feederhouse Reverser driver detects an open, short, over voltage, or over temperature condition.

E03

200112

04

E03

200126

11

E03

200128

03

E03

200128

04

E03
E03
E03
E03
E03
E03

200129
200132
200133
200134
200135
200137

11
11
11
11
11
11

3
1
1
1
1
2

Continued on next page

OUO6075,0001977 1924JUL0124/25
101801

30-19

PN=137

Calibration Procedures
Control Unit
E03
E03

SPN
200140
200141

FMI
03
04

Pri.
2
2

Description
12VDC detected on Power Ground (cc# 010) of Control Relay Board. Indicates problem with ground connections.
12VDC not detected on Unswitched Electronic Power (cc# 022) of Control Relay Board. Indicates problem with Unswitched Electronic Power connection, wiring or Fuse F20 of the Engine Compartment Relay Panel.
12VDC not detected on Light Power (cc# 014) of Control Relay Board. Indicates problem with Light Power connection, wiring or Fuse F18 of the Engine Compartment Relay Panel.
12VDC not detected on Control Power (cc# 016) of Control Relay Board. Indicates problem with Control Power connection, wiring, Fuse F8 or Relay K4 of the Engine Compartment Relay Panel.
12VDC not detected on Light Power 2 (cc# 046) of Control Relay Board. Indicates problem with Light Power 2 connection, wiring or Fuse F5 of the Engine Compartment Relay Panel.
12VDC not detected on Light Power 3 (cc# 047) of Control Relay Board. Indicates problem with Light Power 3 connection, wiring or Fuse F3 of the Engine Compartment Relay Panel.
12VDC not detected on Light Power 4 (cc# 048) of Control Relay Board. Indicates problem with Light Power 4 connection, wiring or Fuse F4 of the Engine Compartment Relay Panel. (9540, 9640, 9560, 9660, 9580, 9680, 9780 and 9880 STS)
12VDC not detected on Fan Speed Adjust Power (cc# 051) of Control Relay Board. Indicates problem with Fan Speed Adjust Power connection, wiring or Fuse F11 or Relay K5 of the Engine Compartment Relay Panel.
12VDC not detected on Light Power 5 (cc# 049) of Control Relay Board. Indicates problem with Light Power 5 connection, wiring or Fuse F9 of the Engine Compartment Relay Panel.
Indicates a problem in the serial communication link between the Left Control Unit and the Control Relay Board.

E03
E03
E03
E03
E03

200142
200143
200144
200145
200146

04
04
04
04
04

2
2
2
2
3

E03

200147

04

E03
E03

200148
200149

04
11

2
2

E04 - Left Control Unit 2 Diagnostic Trouble Codes


Control Unit
E04
E04
E04
E04
E04
E04
E04
E04

SPN
190
627
630
1500
1503
200150
200151
200152

FMI
09
03
11
09
09
11
11
11

Pri.
3
1
3
3
2
3
3
3

Description
CAN Bus message(s) missing from Engine Control Unit - Engine Speed
Delayed Power (cc# 006) voltage is too high - greater than 15.5 VDC.
EEPROM failed test on power up. Replace the Left Control Unit 2 if condition persists.
CAN Bus message(s) missing from Cornerpost Control Unit
CAN Bus message(s) missing from Armrest Control Unit
Threshing Speed failed to reach commanded speed after 50 seconds
Threshing Clearance failed to reach commanded clearance after 30 seconds
Cleaning Fan Speed failed to reach commanded speed after 130 seconds

OUO6075,0001977 1924JUL0125/25

30-20

101801

PN=138

Calibration Procedures

Header Width Calibration


NOTE: On corn heads the display format is number of rows on the second line and row spacing on the third line. Row spacing units are mm for the metric system and inches for the English system. On cutting platforms the format is header width on the third line. Units are meters for the metric system and feet for the English system.
Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,0000286 1908DEC001/6

Press the up or down arrow switch until E01 appears on the tachometer.

OUO6075,0000286 1908DEC002/6

Press the enter switch.

Continued on next page

OUO6075,0000286 1908DEC003/6

30-21

101801

PN=139

ZX018990

UN15NOV99

ZX018989

UN15NOV99

ZX018729

UN15NOV99

Calibration Procedures
Press the up or down arrow switch until 125 appears on the tachometer.

OUO6075,0000286 1908DEC004/6

Press the enter switch. Input the desired value: The first available number of the value will flash (on middle or lower line depending on header type) Input for cutting platforms - meters for the metric system and feet for the English system Input for corn head spacing - mm for the metric system and inches for the English system Input for corn head - number of rows Press the up arrow and down arrow switches on the display to increase or decrease the value of the flashing digit When the desired value is flashing, press the calibrate button to move to the next digit Continue changing the value, one digit at a time until the desired value is shown on the tachometer Press enter switch to enter the new value into memory

OUO6075,0000286 1908DEC005/6

Return to normal operation: Press the back arrow switch on the VISIONTRAK monitor twice to return to normal operation Turn the key switch OFF The next time the machine is started, this calibration information will be used by the combine

OUO6075,0000286 1908DEC006/6

30-22

101801

PN=140

ZX018740

UN26NOV99

ZX018990

UN15NOV99

ZX018991

UN15NOV99

Calibration Procedures

Header Calibration
The header calibration procedure must be performed when a header is initially hooked up and when header height sensors or the pressure sensor are replaced. If the header has no height sensors, this procedure can be used to set the feeder house angle at which the header is on the ground, to calibrate the display for return-to-cut operation. See the angle sensor calibration procedure for calibrating the tilt angle sensor. Prepare Header For Calibration: Hook up header to the combine and ensure header harness is connected to combine harness. Check that the header height sensors are in working condition. Move the machine onto a level concrete surface.

OUO6075,000034B 1908JAN011/10

1- Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,000034B 1908JAN012/10

2- Press the calibration switch. CAL and ACF will appear on the tachometer.

Continued on next page

OUO6075,000034B 1908JAN013/10
101801

30-23

PN=141

ZX018730

UN25FEB00

ZX018729

UN15NOV99

Calibration Procedures
3- Press the up or down arrow switch to access the hdr calibration mode. CAL and hdr appear on the tachometer.

OUO6075,000034B 1908JAN014/10

4- The header may be moved with the header lift switch on the multifunction lever. Lower the header until it rests on the ground. Tilt the header if necessary so that the ends of the header contact the ground at the same time.

OUO6075,000034B 1908JAN015/10

5- Press the enter switch. hdr and Sr should appear on the tachometer. If the header has no height sensors and is being calibrated for the display for return to cut only, go to step 6. Otherwise skip the step 6 and go to step 7.

Continued on next page

OUO6075,000034B 1908JAN016/10
101801

30-24

PN=142

ZX019024

UN25FEB00

H68476

UN07JUN01

ZX019018

UN25FEB00

Calibration Procedures
6- Press the enter switch. hdr and EOC should appear on the tachometer. Skip to the step 9.
UN25FEB00

OUO6075,000034B 1908JAN017/10

7- Press and hold the header lift switch (slow raise) on the multifunction lever. The header will slowly rise until the height sensors lose contact with the ground. After the header stops moving, the tachometer should display hdr and S-L.

Continued on next page

OUO6075,000034B 1908JAN018/10
101801

30-25

PN=143

ZX019026

UN25FEB00

H68476

UN07JUN01

ZX019025

Calibration Procedures
8- Press and hold the header lift switch (slow lower) on the multifunction lever. The header will lower until it rests on the ground. After the header stops moving, the tachometer should display hdr and EOC.

Continued on next page

OUO6075,000034B 1908JAN019/10

30-26

101801

PN=144

ZX019027

UN25FEB00

H68476

UN07JUN01

Calibration Procedures
9- Press the enter switch to store all end of calibration (EOC) values which did not have errors. If no errors occurred during calibration, the following will be displayed: EOC Er00 xxxx cylinder pressure during raise (kPa or psi) xxxx cylinder pressure during lower (kPa or psi) END
UN15NOV99

If any errors occurred during calibration, previous calibration values are kept and the following will be displayed: EOC Err END Press the back arrow switch twice to return to normal operation.

OUO6075,000034B 1908JAN0110/10

30-27

101801

PN=145

ZX018990

Calibration Procedures

Angle Sensor Calibration


The angle sensor is calibrated using this procedure. The calibration procedure must be performed when the sensor is replaced or when the display is not accurate. Prepare Machine For Calibration: Make sure the sensor is operating. Start the combine and raise the header completely.

OUO6075,0001528 1921FEB011/12

Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,0001528 1921FEB012/12

Press the calibration switch. CAL and ACF will appear on the tachometer.

OUO6075,0001528 1921FEB013/12

Press the up or down arrow switch to access the tiLt calibration mode. CAL and tiLt will appear on the tachometer.

Continued on next page

OUO6075,0001528 1921FEB014/12
101801

30-28

PN=146

ZX018741

UN15NOV99

ZX018730

UN25FEB00

ZX018729

UN15NOV99

Calibration Procedures
Press the enter switch. tiLt and L - dn will appear on the tachometer.

OUO6075,0001528 1921FEB015/12

To establish the left tilt sensor setting: Press and hold the left side of the lateral tilt switch (A) until the feeder house rotates completely to the left. This establishes the left tilt sensor setting.
ALateral Tilt Switch

OUO6075,0001528 1921FEB016/12

Press the calibration button. tiLt and r - dn will appear on the tachometer.

Continued on next page

OUO6075,0001528 1921FEB017/12
101801

30-29

PN=147

ZX018744

UN15NOV99

H68477

UN07JUN01

ZX018742

UN15NOV99

Calibration Procedures
To establish the right tilt sensor setting: Press and hold the right side of the lateral tilt switch (A), until the feeder house rotates completely to the right. This establishes the right tilt sensor setting.
ALateral Tilt Switch

OUO6075,0001528 1921FEB018/12

Press the calibration switch. tiLt and cntr will appear on the tachometer.

Continued on next page

OUO6075,0001528 1921FEB019/12

30-30

101801

PN=148

ZX018745

UN15NOV99

H68478

UN07JUN01

Calibration Procedures
Use the lateral tilt switch (A) to level the feeder house. For a visual indication of whether the header is level with the combine chassis, the feeder house is equipped with a manual indicator.
UN13SEP00

When the notch (B) is in the center of the rubber seal on standard combine, the header is approximately level with the combine body. When symbol (C) indicates the feeder house is horizontal but the notch (B) is not in the center of the rubber seal, adjust sensor cable. (See HEADERTRAK SENSOR CABLE ADJUSTMENT).
ALateral Tilt Switch BNotch CSymbol

Standard Combine Notch

OUO6075,0001528 1921FEB0110/12

Press the calibration switch. EOC will appear on the display.

Continued on next page

OUO6075,0001528 1921FEB0111/12
101801

30-31

PN=149

ZX018739

UN15NOV99

H68479

UN06JUN01

H54617

UN14APR99

ZX022460

Calibration Procedures
Press the enter switch to store the calibration value or press the back arrow switch to abort the calibration (and not save values). Press the back arrow switch to return to normal operation.
UN15NOV99

OUO6075,0001528 1921FEB0112/12

HEADERTRAK Sensor Cable Adjustment


Sensor cable (A) needs to be adjusted when notch (B) is not in the center of the rubber seal while symbol (C) indicates the feeder house is horizontal. When the notch (B) is in the center of the rubber seal (the header is approximately level with the combine body) and symbol (C) indicates the feeder house is horizontal, sensor cable (A) is adjusted correctly.
ASensor Cable BNotch CSymbol
UN26NOV99

OUO6075,0001529 1921FEB011/1

30-32

101801

PN=150

H68479

UN06JUN01

H54617

UN14APR99

ZX019057

ZX018734

Calibration Procedures

Machine Harvesting Threshold Calibration


The area counter is switched off above this header height value. Prepare Header For Calibration: Make sure header harness is connected to combine harness

OUO6075,0000352 1908JAN011/9

Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,0000352 1908JAN012/9

Press the calibration switch. CAL and ACF will appear on the tachometer.

OUO6075,0000352 1908JAN013/9

Press the enter switch.

Continued on next page

OUO6075,0000352 1908JAN014/9
101801

30-33

PN=151

ZX018990

UN15NOV99

ZX018730

UN25FEB00

ZX018729

UN15NOV99

Calibration Procedures
Press the up or down arrow switch until CAL and ACAL appear on the tachometer.

OUO6075,0000352 1908JAN015/9

Press the enter switch.

Continued on next page

OUO6075,0000352 1908JAN016/9

30-34

101801

PN=152

ZX018990

UN15NOV99

ZX018992

UN25FEB00

Calibration Procedures
Display will show current machine threshold in the units shown on the corner post header display. Raise or lower the header to the desired position for the not harvesting signal to be generated.
UN16NOV99

OUO6075,0000352 1908JAN017/9

Press calibration switch to save the new position. New threshold will be displayed for 2 seconds, then EOC will be displayed. End of calibration (EOC) shows that the calibration was successful.
UN15NOV99

Continued on next page

OUO6075,0000352 1908JAN018/9
101801

30-35

PN=153

ZX018739

H68476

UN07JUN01

ZX018995

Calibration Procedures
Press twice the enter switch to save the calibration values and return to normal operation or press the back arrow switch to abort the calibration (and not save values). Press the back arrow switch to return to normal operation.
UN15NOV99

OUO6075,0000352 1908JAN019/9

30-36

101801

PN=154

ZX018734

Calibration Procedures

Float Calibration (For Header With Sensors)


The pressure sensor is calibrated for the header installed on the combine in the float system calibration procedure. The float calibration procedure must be performed when a header is initially hooked up if the ground pressure (float) mode of operation will be used. Prepare Header For Calibration: Turn the key switch to the run position. Hook up header to the combine and ensure header harness is connected to combine harness. Move the machine onto a level surface.

OUO6075,0000354 1908JAN011/8

Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,0000354 1908JAN012/8

Press the calibration switch until CAL and ACF appear on the tachometer.

Continued on next page

OUO6075,0000354 1908JAN013/8

30-37

101801

PN=155

ZX018730

UN25FEB00

ZX018729

UN15NOV99

Calibration Procedures
Press the up or down arrow switch to access the FLO calibration mode. CAL and FLO will appear on the tachometer.

OUO6075,0000354 1908JAN014/8

Press the enter switch to access the float calibration mode. FLO and HFL should appear on the tachometer.

OUO6075,0000354 1908JAN015/8

While in this mode, the feeder house may be moved in open loop control. With the header lift switch on the multifunction lever, lower the header until the cutterbar is about 100 mm (3.94 in.) above ground level (the header must not touch the ground).

Continued on next page

OUO6075,0000354 1908JAN016/8
101801

30-38

PN=156

H68476

UN07JUN01

ZX019020

UN25FEB00

ZX019550

UN25FEB00

Calibration Procedures
Press the calibration switch (the header must not touch the ground) to record the float calibration level. 103 and EOC will appear on the tachometer.

OUO6075,0000354 1908JAN017/8

Press the enter switch to store the float calibration pressure in the header controller. 103 and FCAL will appear on the tachometer. Press the back arrow switch twice to return to normal operation.

OUO6075,0000354 1908JAN018/8

30-39

101801

PN=157

ZX022507

UN13SEP00

ZX022463

UN13SEP00

Calibration Procedures

Float Calibration (For Header Without Sensors)


The pressure sensor is calibrated for the header installed on the combine in the float system calibration procedure. The float calibration procedure must be performed when a header is initially hooked up if the ground pressure (float) mode of operation will be used. Prepare Header For Calibration: Turn the key switch to the run position. Hook up header to the combine and ensure header harness is connected to combine harness. Move the machine onto a level surface.

OUO6075,0000355 1908JAN011/9

Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,0000355 1908JAN012/9

Press the up arrow switch to obtain E01.

Continued on next page

OUO6075,0000355 1908JAN013/9

30-40

101801

PN=158

ZX019017

UN15NOV99

ZX018729

UN15NOV99

Calibration Procedures
Press the enter switch to access the E01 diagnostic mode. 000 and E01 appears on the tachometer.

OUO6075,0000355 1908JAN014/9

Press the calibration switch repeatedly to reach the float calibration mode. 103 and FCAL should appear on the tachometer.

OUO6075,0000355 1908JAN015/9

Press the enter switch to access the float calibration mode. 103 and HFL should appear on the tachometer.

Continued on next page

OUO6075,0000355 1908JAN016/9

30-41

101801

PN=159

ZX019020

UN25FEB00

ZX019019

UN15NOV99

ZX020522

UN14MAR00

Calibration Procedures
While in this mode, the feeder house may be moved in open loop control. With the header lift switch on the multifunction lever, lower the header until the cutterbar is about 100 mm (3.94 in.) above ground level (the header must not touch the ground).

OUO6075,0000355 1908JAN017/9

Press the calibration switch. 103 and EOC will appear on the tachometer.

OUO6075,0000355 1908JAN018/9

Press the enter switch to store the float calibration pressure in the header controller. 103 and FCAL will appear on the tachometer. Press the back arrow switch twice to return to normal operation.

OUO6075,0000355 1908JAN019/9

30-42

101801

PN=160

ZX022507

UN13SEP00

ZX022463

UN13SEP00

H68476

UN07JUN01

Calibration Procedures

Concave Sensor Zero Calibration


The concave position sensor is calibrated using the concave calibration procedure. The concave calibration procedure must be performed before initial use or when the concave sensor is replaced.

NOTE: If the sensor has been replaced, be certain concave and separator are clear of crop material.
Turn the key switch to run position or start the combine. Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,00002C7 1915DEC001/7

Press the calibration switch. CAL and ACF will appear on the tachometer.

OUO6075,00002C7 1915DEC002/7

Press the up or down arrow switch until CAL and conc appear on the tachometer.

Continued on next page

OUO6075,00002C7 1915DEC003/7

30-43

101801

PN=161

ZX019551

UN25FEB00

ZX018730

UN25FEB00

ZX018729

UN15NOV99

Calibration Procedures
Press the enter switch, conc will appear on the upper line of the display. CLOS will appear on the second line of the display.

OUO6075,00002C7 1915DEC004/7

Zero setting: Press and hold the (-) symbol on the concave clearance switch until the concave is completely closed (clicking sound will be heard). As the (-) symbol is being pressed, the numbers in middle line of the display will decrease until the concave is completely closed.

H68480

UN07JUN01

Continued on next page

OUO6075,00002C7 1915DEC005/7

30-44

101801

PN=162

ZX018732

UN04NOV99

ZX018731

UN15NOV99

Calibration Procedures
Press the calibration switch. Zero (0) will be displayed on the tachometer for 2 seconds, then EOC will be displayed.

OUO6075,00002C7 1915DEC006/7

Press the ENTER switch to store the calibration value or press the back arrow switch to abort calibration (and not save values). Press back arrow switch to return to normal operation.
UN15NOV99

OUO6075,00002C7 1915DEC007/7

30-45

101801

PN=163

ZX018734

ZX018733

UN15NOV99

Calibration Procedures

Area Counter Enable Calibration


To enable area counter. Press the diagnostic switch. dIA will appear on the triple display tachometer.

AG,OUZXMAY,220 1913NOV991/6

Press the up or down arrow switch until C03 appears on the tachometer.

AG,OUZXMAY,220 1913NOV992/6

Press the enter switch.

AG,OUZXMAY,220 1913NOV993/6

Press the up or down arrow switch until 122 appears on the tachometer.

Continued on next page

AG,OUZXMAY,220 1913NOV994/6
101801

30-46

PN=164

ZX019009

UN15NOV99

ZX018990

UN15NOV99

ZX019008

UN25FEB00

ZX018729

UN15NOV99

Calibration Procedures
Press the enter switch.

AG,OUZXMAY,220 1913NOV995/6

Input the desired value: The first digit will flash Press the calibration switch The second digit will flash Press the calibration switch The third digit will flash Press the up or down arrow switch until a 1 appears on the tachometer Press the calibration switch The fourth digit will flash Press the calibration switch Press enter switch to enter the new value into memory

Return to normal operation: Press the back arrow switch on the VISIONTRAK monitor twice to return to normal operation Turn the key switch OFF The next time the machine is started, this calibration information will be used by the combine

AG,OUZXMAY,220 1913NOV996/6

30-47

101801

PN=165

ZX018734

UN15NOV99

ZX018993

UN15NOV99

ZX019010

UN16NOV99

ZX018990

UN15NOV99

Calibration Procedures

Field Area Counter Clear Calibration


Press the diagnostic switch. dIA will appear on the triple display tachometer.
UN15NOV99

OUO6075,0000287 1908DEC001/4

Press the calibration switch. CAL and ACF will appear on tachometer

OUO6075,0000287 1908DEC002/4

Press the enter switch. ACF and clr? will appear on tachometer.

OUO6075,0000287 1908DEC003/4

Press the enter switch to erase value and EOC will appear on tachometer for 2 seconds. Press the back arrow switch on the VISIONTRAK monitor once to return to normal operation.
UN25FEB00

OUO6075,0000287 1908DEC004/4

30-48

101801

PN=166

ZX019013

ZX019012

UN25FEB00

ZX018730

UN25FEB00

ZX018729

Calibration Procedures

Field Total Area Counter Clear Calibration


Press the diagnostic switch. dIA will appear on the triple display tachometer.
UN15NOV99

OUO6075,0000288 1908DEC001/5

Press the calibration switch. CAL and ACF will appear on tachometer.

OUO6075,0000288 1908DEC002/5

Press the up arrow switch once. ACFt will appear on the tachometer.

OUO6075,0000288 1908DEC003/5

Press the enter switch. ACFt and clr? will appear on tachometer.

Continued on next page

OUO6075,0000288 1908DEC004/5
101801

30-49

PN=167

ZX019015

UN25FEB00

ZX019014

UN25FEB00

ZX018730

UN25FEB00

ZX018729

Calibration Procedures
Press the enter switch to clear Field Total Area Counter. EOC appears for 2 seconds then CAL and ACFt will appear on tachometer. Press the back arrow switch on the VISIONTRAK monitor once to return to normal operation.

NOTE: Clearing Field Total Area Counter will also clear Field Area Counter.

OUO6075,0000288 1908DEC005/5

30-50

101801

PN=168

ZX019016

UN25FEB00

Calibration Procedures

Deck Plate Sensor Zero Calibration


The deck plate position sensor is calibrated using the deck plate calibration procedure. The deck plate calibration procedure must be performed before initial use or when the deck plate position sensor is replaced. Prepare Header For Calibration: Attach corn head to the combine and attach header harness to the combine harness. Make sure deck plate position sensor is operating. Start the combine.

OUO6075,00002E0 1915DEC001/10

Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,00002E0 1915DEC002/10

Press the calibration switch. CAL and ACF will appear on the tachometer.

Continued on next page

OUO6075,00002E0 1915DEC003/10

30-51

101801

PN=169

ZX018730

UN25FEB00

ZX018729

UN15NOV99

Calibration Procedures
Press the up or down arrow switch until CAL and the dEc calibration mode appear on the tachometer.

OUO6075,00002E0 1915DEC004/10

Press the calibration button. dEc and CLOS will appear on the tachometer.

OUO6075,00002E0 1915DEC005/10

Sensor minimum setting: Press and hold the right side of the reel fore/aft switch (A) until the deck plates are completely closed.
AReel Fore/Aft Switch

Continued on next page

OUO6075,00002E0 1915DEC006/10
101801

30-52

PN=170

H68481

UN07JUN01

ZX018748

UN15NOV99

ZX018747

UN15NOV99

Calibration Procedures
Press the calibration switch until dEc and OPEn appear on the tachometer.

OUO6075,00002E0 1915DEC007/10

Sensor maximum setting: Press and hold the left side of the reel fore/aft switch (A) until the deck plates are completely open.
AReel Fore/Aft Switch

OUO6075,00002E0 1915DEC008/10

Press the calibration switch. EOC will appear on the tachometer.

Continued on next page

OUO6075,00002E0 1915DEC009/10
101801

30-53

PN=171

ZX018739

UN15NOV99

H68481

UN07JUN01

ZX018750

UN15NOV99

Calibration Procedures
Press the enter switch to store the calibration value or press the back arrow switch to abort the calibration (and not save values). Press the back arrow switch to return to normal operation.
UN15NOV99

OUO6075,00002E0 1915DEC0010/10

30-54

101801

PN=172

ZX018734

Calibration Procedures

Tailings Monitor Calibration


The tailings monitor indicates the volume of material in the tailings elevator using lasers and detectors. The sensors determine the average amount of material in the elevator by the amount of light being blocked by material. The master tailings sensor sends a message to the VISIONTRAK display. The tailings elevator is re-zeroed every time the separator is engaged at high engine idle for 2 minutes without the feeder house being engaged. This reoccurs and is stored every 3 seconds until the feeder house is engaged.
UN26NOV99

NOTE: The sensitivity of the tailings elevator volume calibration is affected by the seed size selected for the grain loss monitor. The scaling of the tailings monitor can be altered through the diagnostic system on the corner post.

OUO6075,0000357 1908JAN011/1

30-55

101801

PN=173

ZX018685

Calibration Procedures

Chopper Vane Angle Calibration


The chopper vane angle calibration must be performed when the electrical motor is replaced.
UN15NOV99

Turn the key switch to the run position. Press the diagnostic switch. dIA will appear on the triple display tachometer.

OUO6075,00014B7 1921FEB011/9

Press the up arrow switch to obtain E02.

OUO6075,00014B7 1921FEB012/9

Press the enter switch to access the E02 diagnostic mode. 000 and E02 appears on the tachometer.

OUO6075,00014B7 1921FEB013/9

Press the calibration switch repeatedly to reach the chopper vane calibration mode. 115 and ICAL should appear on the tachometer.

Continued on next page

OUO6075,00014B7 1921FEB014/9
101801

30-56

PN=174

ZX022467

UN13SEP00

ZX022466

UN13SEP00

ZX022465

UN13SEP00

ZX018729

Calibration Procedures
Press the enter switch to access the float calibration mode. 115 and L - - - should appear on the tachometer. Press chopper vane adjust switch (A) to left-hand side to fully orientate the vanes to the left.
AChopper Vane Adjust Switch (Optional)
UN13SEP00

OUO6075,00014B7 1921FEB015/9

Press the calibration switch. 115 and - - - r will appear on the tachometer. Press chopper vane adjust switch (A) to right-hand side to fully orientate the vanes to the right.
AChopper Vane Adjust Switch (Optional)
UN13SEP00

Continued on next page

OUO6075,00014B7 1921FEB016/9
101801

30-57

PN=175

H68483

UN07JUN01

ZX022470

H68482

UN07JUN01

ZX022468

Calibration Procedures
Press the calibration switch. 115 and cntr will appear on the tachometer. Press chopper vane adjust switch (A) to left-hand side until the vanes are centered.
AChopper Vane Adjust Switch (Optional)
UN13SEP00

OUO6075,00014B7 1921FEB017/9

Press the calibration switch. 115 and EOC will appear on the tachometer.

OUO6075,00014B7 1921FEB018/9

Press the enter switch to store the calibration value or press the back arrow switch to abort calibration (and not save values). Press back arrow switch to return to normal operation.
UN15NOV99

OUO6075,00014B7 1921FEB019/9

30-58

101801

PN=176

ZX018734

ZX022473

UN13SEP00

H68482

UN07JUN01

ZX022472

Calibration Procedures

Clock Calibration
The clock calibration must be performed when battery was disconnected or the battery switch was moved to OFF position. Preparations For Clock Calibration: Battery is connected Battery switch is in ON position

AG,OUZXMAY,203 1917FEB001/8

Press the diagnostic switch. dIA will appear on the triple display tachometer.

AG,OUZXMAY,203 1917FEB002/8

Press the calibration switch. CAL and ACF will appear on the tachometer.

AG,OUZXMAY,203 1917FEB003/8

Press the up or down arrow keys until CAL and cLc appears on the tachometer.

Continued on next page

AG,OUZXMAY,203 1917FEB004/8
101801

30-59

PN=177

ZX018969

UN15NOV99

ZX018730

UN25FEB00

ZX018729

UN15NOV99

Calibration Procedures
Press the enter switch to access the clock calibration mode. cLc and 00:00 will appear on the tachometer and the first digit will flash.

AG,OUZXMAY,203 1917FEB005/8

Press the up or down arrow keys to adjust. Press the calibration switch, the second digit will flash. Continue in the same manner until the fourth digit will flash.

Continued on next page

AG,OUZXMAY,203 1917FEB006/8

30-60

101801

PN=178

ZX018971

UN15NOV99

ZX018970

UN15NOV99

Calibration Procedures
Press the up or down arrow keys to adjust. Press the calibration switch. EOC will appear on the tachometer.

AG,OUZXMAY,203 1917FEB007/8

Press the enter switch to store the calibration value or press the back arrow switch to abort calibration (and not save values). Press back arrow switch to return to normal operation.
UN15NOV99

AG,OUZXMAY,203 1917FEB008/8

30-61

101801

PN=179

ZX018734

ZX018972

UN25FEB00

Calibration Procedures

Clear Service (SEU) Indicator


At the end of every 50 hours of operation, a reminder is displayed on the tachometer. The letters SEU appear for this purpose. After performing the proper maintenance, clear the display with the following procedure. Prepare Combine:
UN12NOV99

Turn the key switch to the run position.

AG,OUZXMAY,224 1917FEB001/4

Press the diagnostic switch. dIA will appear on the triple display tachometer.

AG,OUZXMAY,224 1917FEB002/4

Press the up arrow switch once. SEU and clr? appear on the tachometer.

Continued on next page

AG,OUZXMAY,224 1917FEB003/4

30-62

101801

PN=180

ZX018997

UN25FEB00

ZX018729

UN15NOV99

ZX018752

Calibration Procedures
Press the enter switch to clear the service indicator. SEU and donE will appear on the tachometer. Press back arrow switch to return to normal operation.
UN02DEC99

AG,OUZXMAY,224 1917FEB004/4

30-63

101801

PN=181

ZX018998

Operators Station
Access Ladder to Operators Cab
The ladder can be positioned from the ground or the landing with lever (A). Swing ladder forward or rearward. The ladder will lock into place (3 positions). CAUTION: Do not ride or attempt to climb front or rear ladders while combine is moving. If the ladder latch appears loose, clean out the latch pin area. Do not use oil or grease in this area.
ALever
UN20FEB01

OUO6075,0001488 1920FEB011/1

Cab Ladder Positions


Normal operating field position (A). Pull down latch and swing ladder to position (B) for combines with a small header, a ladder extension or duals. From the cab landing, push down on the latch and swing ladder to position (D) before driving on roadways. CAUTION: Always swing ladder to position (D) before transporting on public roadways in order to reduce combine width and position amber warning lamp toward oncoming motorists. IMPORTANT: The long ladder extension 1390 mm (55 in) is required on machines equipped with dual tires, axle spacers, etc. will interfere with the platform drive shaft when the ladder is swung to position (D). Raising or lowering the feeder house could damage the ladder, the drive shaft or the drive shaft shield. Place ladder in position (C) in this situation.

AField Position BSmall Header, Ladder Extension or Duals Position CRoadway Driving Position for Long Ladder Extension DRoadway Driving Position

OUO6075,000003D 1924JAN011/1

35-1

101801

PN=182

H63874

UN09MAY00

H66509

Operators Station

Cab Landing Safety Chains


Safety chains (A) must be tight when ladder is in the full forward position. Adjust chains with pins (B).
AChains BPins

AG,OUZXMAY,228 1918NOV991/1

Washing Cab Windows, Servicing Head Lights and Wiper


Use ladder and landing to clean left side of cab. CAUTION: Raise feeder house completely and install safety stop on left-hand side feeder house lift cylinder. Close cab door securely and use hand holds. IMPORTANT: Do not manually move the wiper arm, this could cause damage to the wiper mechanism. Stand on raised feeder house to clean front cab window and service head lights or wiper. For stability, use handrails (A) on either side of the cab and handholds (B) on either side of the wiper. Access feeder house by using step on left-hand side. Use step and landing to clean right side of cab.
AHandrails BHandholds

OUO6075,0000063 1917NOV001/1

35-2

101801

PN=183

H52396

UN06JUL99

H52395

UN06JUL99

H57079

UN12MAY99

Operators Station

Right-Hand Side Cab Access


Raise feeder house. CAUTION: Engine must be off, key removed and parking brake set. Turn engine off, remove key and lower safety stop. IMPORTANT: Close cab door before using safety rail next to cab door. Use step (A) to get to landing (B).
AStep BLanding

OUO6075,0001769 1930MAY011/1

Grain Tank Window/Rear Cab Window Cleaning


CAUTION: Engine must be off, key removed and parking brake set. Loosen clamps (A) and swing grain tank window (B) up for cleaning.
AClamps BGrain Tank Window
UN24JAN01

OUO6075,000152A 1921FEB011/1

35-3

101801

PN=184

H65907

H67449

UN20APR01

Operators Station

Armrest Storage Box


The armrest lid lifts for storage. Keep your COMBINE SETTINGS card in this storage box (A). Decal (B) shows engine starting information.
AStorage Box BDecal

OUO6075,000037B 1909JAN011/1

Manual Storage
Keep your manuals (A) and combine settings card (B) in the holder located on the rear cab wall.
AManuals BCombine Settings Card

OUO6075,0000064 1917NOV001/1

GREENSTAR Printer (Optional)


A print out from the GREENSTAR yield monitoring, and yield mapping system will be generated.

GREENSTAR is a trademark of Deere & Company.

OUO6075,00013DB 1902FEB011/1

35-4

101801

PN=185

H66149

UN02FEB01

H60922

UN20SEP99

ZX018763

UN26NOV99

Operators Station

GREENSTAR (Attachment)
GREENSTAR yield mapping is a fully integrated precision farming package, which consists of a GREENSTAR display monitor, mass-flow sensor, moisture sensor and mapping processor.

OUO6075,000152B 1921FEB011/1

Cooling Compartment/Recirculation Filter


Cooling compartment (A) is located in left-hand rear corner of cab. Remove it for access to recirculation air filter.
ACooling Compartment
UN03MAY01

OUO6075,000168B 1903MAY011/1

35-5

101801

PN=186

H67763

UN03MAY01

H67762

ZX018765

UN26NOV99

Operators Station

Emergency Exit
Pull tab (A) to begin removal of rubber rope (B). Continue to pull until rope is removed from around window. The window can now be pushed out and allowed to fall free. See your John Deere dealer for window replacement.
APull Tab BRubber Rope

OUO6075,000037C 1909JAN011/1

Cab Interior Lights


AFront Console and Armrest Console Light BDome Light CDome Light Switch
UN26NOV99

AG,OUZXMAY,191 1901NOV991/1

Auxiliary Power Outlet Strip and SERVICE ADVISOR Diagnostic Connector


The auxiliary power outlet strip (A) with six additional electrical outlets is located at the lower rear of the right-hand side window, provides key-switched or unswitched power. The maximum combined current draw for all outlets is 30 amps. A SERVICE ADVISOR diagnostic connector (B) is also provided.
AAuxiliary Power Outlet Strip BSERVICE ADVISOR Diagnostic Connector
UN28APR99

SERVICE ADVISOR is a trademark of Deere & Company

OUO6075,0000068 1917NOV001/1

35-6

101801

PN=187

H52406

ZX018770

ZX018636

UN12NOV99

Operators Station

Field Office Seat


In place of the standard instructional seat, a field office seat option is available. It contains a storage folder and removable tray for items such as cassettes, CDs, and cell phones. When the tray is removed, the compartment is sized to hold a lap top computer.
UN02APR01

OUO6075,00018E5 1928JUN011/1

Cooling Compartment
The cooling compartment (A) is located behind the passenger seat and provides space for bottles etc. (e.g. two 1.5-L bottles).
ACooling Compartment
UN27APR01

OUO6075,000152C 1921FEB011/1

35-7

101801

PN=188

H67703

H67083

Operators Station

COMFORTCOMMAND Operators Seat


The COMFORTCOMMAND operators seat has an air suspension system for added operator comfort. The seat has a self-contained electric compressor to adjust the seat suspension to match the operators height and weight. The seat has ten main adjustments: Vertical Shock Dampener Height Adjustment Fore/Aft Adjustment Fore/Aft Attenuator Lock-Out Seat Bottom Tilt Seat Back Tilt Seat Back Lumbar Support Left Hand Armrest Fore/Aft Seat Cushion Adjustment Automatic Seat Height Adjustment (Weight Based)

OUO6075,00015AA 1902APR011/1

35-8

101801

PN=189

H67068

UN02APR01

Operators Station

Seat Suspension and Forward and Rearward Adjustment


Vertical shock dampener lever (A) allows the operator to limit the amount of upward motion the seat suspension provides. Push the control forward for the softest ride. Move the lever back for the firmest ride. Between these two positions is the medium firmness position. Height adjustment is made with lever (B). To raise the seat, pull up on the lever. To lower the seat, push down on the lever.
UN12SEP01

NOTE: The suspension can be adjusted to reach limits in the minimum and maximum heights which, in effect, locks out the suspension system, making it rigid. The suspension height control will also hit the limits if adjusted too close to the extremes.
The forward/rearward adjustment lever (C) allows the seat to slide forward or rearward for best working position. Seat bottom tilt control lever (D), allows the front of the seat cushion to be raised or lowered for the best working position. Attenuator lockout lever (E) locks out or releases the forward or rearward movement. Pull up on the lever to lock; push down on the lever to release. The forward/rearward adjustment lever (F) allows the seat bottom to slide forward or rearward for the best working position.

AVertical Shock Dampener Control BHeight Adjustment Knob CForward/Rearward Adjustment Lever DSeat Bottom Tilt Control Lever EForward/Rearward Attenuator Lock-Out Lever FSeat Bottom Forward/Rearward Adjustment Lever

NOTE: If the seat does not float or pump up, see your John Deere dealer.
The air seat also has the operators presence system.

OUO6075,00015A9 1902APR011/1

35-9

101801

PN=190

H67071

Operators Station

Adjusting Left-Hand Armrest and Seat Back


To adjust the left-hand armrest up or down, use knob (A). Rotate the knob clockwise to lower and counter clockwise to raise. Pull up on lever (B) to adjust seat back angle. Release lever when seat back is in desired position. Turn knob (C) clockwise or counter clockwise to adjust lumbar back support.
ALeft-Hand Armrest Adjustment Knob BSeat Back Angle Adjustment Lever CLumbar Back Support Adjustment Knob

OUO6075,00015AB 1902APR011/1

Adjusting Right-Hand Armrest and Control Console


A single control moves the right-hand armrest and control console. To adjust the armrest, push in on knob (A) and rotate either direction for desired working position.
AKnob
UN12MAY99

AG,OUO1035,1395 1905JAN001/1

35-10

101801

PN=191

H57073

H67081

UN02APR01

Operators Station

Steering Wheel Height Adjusting


CAUTION: Adjust steering wheel only when combine is stopped. Loosen hub. Push or pull wheel to position. Tighten hub to lock. Only a slight tightening of the hub is needed to hold steering wheel in position.

OUO6075,000006C 1917NOV001/1

Steering Column Tilt Adjustment


CAUTION: Adjust column only when combine is stopped. Column is spring loaded to the upright position. Do not step on pedal without holding steering wheel in both hands. Press pedal to release lock on steering column. Put column in desired position. Column locks when pedal is released.

H01,9000OS,BX 1923AUG971/1

35-11

101801

PN=192

H59555

UN18AUG99

H52419

UN03MAY99

Operators Station

Manual Parking Brake


IMPORTANT: The combine is equipped with manual engage and disengage parking brake pedals. Be certain to engage the parking brake when engine is running and combine is parked and before leaving the combine with the engine turned off. Press pedal (A) to engage the parking brake and pedal (B) to disengage the parking brake.
APedal BPedal

AG,OUO1035,637 1910MAY991/1

Brake Pedals
Leave brake pedals (A) unlocked for field use. Lock brake pedals together with lock (B) for transporting.
APedals BLock (Transport)

OUO6075,00016E7 1918MAY011/1

Filling Windshield Washer Reservoir (Attachment)


Remove cap (A) and fill reservoir with automotive windshield washer solution. The windshield washer is offered for use only with the optional full view wiper.
ACap
UN26NOV99

AG,OUZXMAY,193 1901NOV991/1

35-12

101801

PN=193

ZX018774

H68175

UN22MAY01

H59557

UN18AUG99

Lights and Signals


Light Switches
(A) Dimmer, for all cab interior lights. (B) Hazard Warning: for all position lights on combine. (C) Road: Warning (flashing) and four head lights, instrument lights, tail lights and turn signals when turn signal lever is used. (D) Field: Grain tank and header lights (field position), auxiliary field lights, auger tube light and side finder lights on. (E) Rear: Rear residue discharge lights

NOTE: The combine is equipped with exit lighting. Two head lamps (F) will remain on for 90 seconds after the lights are turned off, operator leaves the seat and the key is removed.
ADimmer for Cab Interior Lights BHazard Warning Lights CRoad Lights DField Lights ERear Lights FHeadlamps
UN12NOV99

OUO6075,00014A1 1921FEB011/1

Cab Interior Lights


The dome light switch (A) controls the dome light (B). The dome light switch has three positions on (left), off (center), and automatic (right) (when the cab door is open).
ADome Light Switch BDome Light

HX,AG,SF6877 1923AUG991/1

40-1

101801

PN=194

H60932

UN04OCT99

ZX018780

H66162

UN21FEB01

Lights and Signals

Dimmer Switch
NOTE: If dimmer switch is in lowest or highest setting, combine exiting lighting will not be activated.
UN29SEP99 H60933

The dimmer switch controls the brightness of the following lights. For more light move switch to BRIGHT and less light move switch to DIM. Overhead Console Light (green light in the dome light assembly) Light Switches in overhead control panel Radio Right Hand Corner Post Right Hand Armrest Multi- Function Lever Mode Control Switch in overhead control panel Wiper Switch in overhead control panel

HX,AG,SF7325 1926JAN001/1

40-2

101801

PN=195

Lights and Signals

Warning Lights
The two position (on and off) warning light switch controls all warning lights on combine and the licence light.
UN12NOV99

When transporting on a road, position lights give warning to other drivers. These lights are located on both sides at the front and rear of the combine. CAUTION: Lights must be turned on when transporting. Road traffic regulations in some countries require that the hazard warning lights must be switched on whenever the combine is stopped at the side of the road.
AWarning Lights, Off BWarning Lights, On

Warning Light Switch

Warning Lights, Front

Warning Lights, Rear


OUO6075,0001782 1931MAY011/1

40-3

101801

PN=196

H68363

UN31MAY01

H65912

UN24JAN01

ZX018781

Lights and Signals

Road Lights
The three position road light switch controls warning lights, instrument lights and turn signals when turn signal lever is used (middle switch position).
ARoad Lights, Off BRoad Lights, On CBeacon Lights On

Road Light Switch

Warning Lights, Front

Warning Lights, Rear


Continued on next page

OUO6075,00018E6 1928JUN011/2
101801

40-4

PN=197

H68363

UN31MAY01

H65912

UN24JAN01

ZX018786

UN26NOV99

Lights and Signals

CAUTION: Lights must be turned on when transporting.

The three position road light switch also controls beacon lights and road lights (top switch position).

Front Beacon Light and Road Lights

Beacon Light, Rear

Road Lights

French Road Lights


OUO6075,00018E6 1928JUN012/2

40-5

101801

PN=198

H69021

UN03JUL01

ZX022479

UN13SEP00

H67694

UN26APR01

H67693

UN26APR01

NOTE: French combines will have two beacon lights on the front of the combine and two beacon lights on the rear of the combine.

Lights and Signals

Field Lights
The two position (on and off) field light switch controls warning lights, all headlights, grain tank light and unloading auger light. Unloading Auger Light Only operates when the field light switch is in on position and the auger is swung out at least 10 degrees. Grain Tank Light
Field Light Switch
UN12NOV99

The grain tank light operates with the field light switch.
AField Lights, Off BField Lights, On

All Headlights

Grain Tank Light

Unloading Auger Light


Continued on next page

OUO6075,00018E7 1928JUN011/2
101801

40-6

PN=199

ZX018792

UN02DEC99

H68556

UN06JUN01

ZX022480

UN13SEP00

ZX018790

Lights and Signals


The two position (on and off) field light switch controls also the side finder lights and the row finder lights. Side Finder Lights
UN11JAN01

The side finder lights are used when additional light to the sides is needed. These lights are controlled by the turn signal lever and operate only when the light switch is in either of the field light positions.
Side Finder Lights

These lights do not work when the flashing warning lights are on. Row Finder Lights Additional lights are available for better overall visibility of the ends of the header and for improved visibility in front of the header. The lights are attached to the left-hand and right-hand side handrails on each side of the cab.
Row Finder Light, R.H.

Row Finder Light, L.H.

OUO6075,00018E7 1928JUN012/2

40-7

101801

PN=200

H65913

UN24JAN01

H65912

UN24JAN01

H65803

Lights and Signals

Stubble and Residue Lights


Three position switch. Lower position turns lights off, middle position for stubble lights (A) only and top position for stubble and rear residue lights (B). CAUTION: To avoid motorist confusion, do not operate work lights when transporting on public roadways.
AStubble Lights BRear Residue Lights

WORK

H52437

UN24MAR99

AG,OUO1035,1413 1905JAN001/1

Unloading Auger Rear Tail/Stop Light


The unloading auger rear warning light (A) provides a warning to motorists when the combine is being transported.
AAuger Warning Light
UN31MAY01

H52439

UN24MAR99

H52438

UN13JUL99

OUO6075,000165C 1918APR011/1

40-8

101801

PN=201

H67585

Lights and Signals

Turn Signals
When operating combine on road or highway, use turn signals.

NOTE: The turn signals only operate in the warning and road light positions. The turn signals are not self cancelling so the lever must be moved back to neutral.
With light switch lever on (hazard or road position), warning light flashers will operate at 60 flashes per minute. When turn signal is set for right-hand turn, the right-hand warning light will flash 90 flashes per minute while the left-hand warning light stays on (not flashing). The opposite happens for left-hand turn.

NOTE: The indicator light on the steering column glows steadily and indicates a turn.

OUO6075,0001678 1926APR011/1

Exit Lighting
NOTE: If dimmer switch is in lowest or highest setting, combine exiting lighting will not be activated.
To allow the operator to exit the combine, two head lights will remain on for approximately 90 seconds after the road or field lights are turned off and the ignition key is removed. To illuminate the sides of the combine, the left or right side finder lights can also be turned on using the turn signal lever. The light will shut-off after 90 seconds. Exiting lighting is activated anytime when the road or field lights are used five minutes prior to turning off the ignition key.

OUO6075,0001750 1930MAY011/1

40-9

101801

PN=202

H68018

UN31MAY01

ZX018967

UN15NOV99

Lights and Signals

Unloading Auger Light


Only operates when either the field or the work light switch is on and the auger is swung out at least 10 degrees.
UN15DEC98

HX,AG,SF6884 1905NOV901/1

40-10

101801

PN=203

H42346A

Lights and Signals

Work Lights (Optional)


CAUTION: Avoid motorist confusion. Do not operate work lights when transporting on public roadways. Additional work lights are available for better visibility of the separator area and engine platform. Work lights (A) are provided on both sides of the combine under the gull wing doors and on the engine platform. The separator lights on and off switch (B) is located above the tailings elevator. On and off switch (C) for the engine platform lights is located on the right hand side of the combine near the rear ladder.
AWork Lights BSeparator Light On/Off Switch CEngine Platform Light On/Off Switch
UN08MAY01 UN28JAN99

Left Hand Door Light

Engine Platform Light

Side Work Light Switch

Engine Platform Light Switch


OUO6075,000176D 1931MAY011/1

40-11

101801

PN=204

H51689

UN28JAN99

H68020

UN16MAY01

H67103

H51687

Lights and Signals

Rear Residue Discharge Lights


CAUTION: To avoid motorist confusion do not operate rear discharge lights on public roadways. The rear lights (A) directs light rearward over the residue discharge area of the combine. The rear lights also allows the operator to see what is behind the combine when backing up at night.
Left-hand Side Rear Discharge Light
ARear Residue Discharge Lights
UN31MAY01

Right-hand Side Rear Discharge Light


OUO6075,000176E 1931MAY011/1

Cleaning Shoe Lights


The lights (A) (one on each side) illuminates the cleaning shoe area for easier adjustment or maintenance. The on/off switch (B) is located above the tailings elevator.
ACleaning Shoe Lights BOn/Off Switch
UN18AUG99

OUO6075,00016B7 1915MAY011/1

40-12

101801

PN=205

H68023

UN16MAY01

H59562

H68022

UN16MAY01

H68368

Lights and Signals

Service Power Receptacles (Optional)

ARight Hand Side Wiring Harness

BEngine Compartment Receptacle

CLeft Hand Side Wiring Harness

IMPORTANT: Receptacles are powered whenever batteries are connected. Connect the service power receptacles to the wires provided.

These wires are located in the right-hand side wiring harness (A), the engine compartment (B) and left-hand side wiring harness (C).

OUO6075,0001972 1918JUL011/1

40-13

H69332

UN18JUL01

101801

PN=206

Prestarting Checks
Engine Oil Level
Before starting the engine for the first time each day: Check engine oil level. Do not operate engine when oil level is below low mark on dipstick.

NOTE: The oil should be checked with the dipstick pushed all the way into the holder.
Remove dipstick (A) and check oil level. Oil level should be between the ADD and the top of the cross-hatch area on dipstick. If needed, add oil recommended in the Fuel, Lubricants, Coolant and Capacities Section. Do not operate engine with oil level below the ADD mark on dipstick.
ADipstick

OUO6075,000004C 1924JAN011/1

45-1

101801

PN=207

H48132

UN24OCT96

H67106

UN09APR01

Prestarting Checks

Hydrostatic/Hydraulic Oil Levels


Check hydrostatic/hydraulic oil level with header on ground and all cylinders retracted. Oil must cover sight glass (A) and be below top of sight glass (B). Add oil as needed. Do not over fill. With engine off, check hydraulic oil at engine gearcase. Oil must not be below the low mark on dipstick (C). Do not overfill.
ASight Glass BSight Glass CDipstick
UN19FEB99

Hydraulic Oil Level (Engine Gearcase)


HX,AG,SF6891 1902MAR991/1

Coolant Level
Allow engine to cool. Coolant level should be at the COLD mark.

HX,AG,SF6892 1902MAR991/1

45-2

101801

PN=208

H54080

UN19FEB99

H54082

UN19FEB99

H54081

Prestarting Checks

Fuel Level
Turn ignition on and check fuel level on the digital tachometer module.
Combine Models
9540, 9640, 9560, 9660, 9580, 9680

Capacity
700 L (185 US gal.)

OUO6075,000176F 1931MAY011/1

Fuel System (9540 Combine)


Draining water out of water trap (A) and engine filters. (See Service-Engine section). If dirty fuel has been used, change filter (B) before changing the engine fuel filters.
AWater Trap BFilter

H52666

UN24MAR99

OUO6075,00018E8 1928JUN011/1

Fuel System
Draining water out of water trap (A) and engine filters. (See Service-Engine section). If dirty fuel has been used, change filter (B) before changing the engine fuel filters.
AWater Trap BFilter

OUO6075,00015B4 1902APR011/1

45-3

101801

PN=209

H67107

UN09APR01

H69333

UN18JUL01

Prestarting Checks

After Long Storage Period


Bleed fuel system to remove air (See Engine Service section). Grease combine and header.

OUO6075,000152E 1921FEB011/1

Tires
Check tires daily for cuts or tears and obvious signs of low pressure. Measure the tire pressure at least once a week using an accurate tire pressure gauge.
INFLATION PRESSURE
Drive Tires
Tire Size Ply Rating/Code
kPa
24.5-32
650/75R32
650/75R32
650/75R32
30.5L-32
800/65R32
800/65R32

Air Pressure
PSI
39
44
58
58
32
29
44

16Ply
167 A8
170 A8
172 A8
16Ply
A8
172 A8

270
300
400
400
220
200
300

Steering Tires
16.5/85-24
18.4-26
480/80R26
540/65R30
540/65R30

8Ply
12Ply
160 A8
150 A8
150 D

190
290
320
300
240

28
42
46
44
35

ZX,OMCTS 011872 1901SEP981/1

45-4

101801

PN=210

Prestarting Checks

Lubricate Combine
Proceed according to the lubrication chart, (see Lubrication Charts, Periodic Service section).
OUO6075,000152F 1921FEB011/1

Checks in Operators Cab


For indicator light and light function checks, refer to Lighting System and Signals Section.
OUO6075,0001530 1921FEB011/1

45-5

101801

PN=211

Prestarting Checks

Start Switch
CAUTION: Sound horn before starting engine to clear people away from the combine. To avoid the possibility of personal injury or death, start the engine ONLY from the operators seat. Do not start engine by shorting across starter terminals. Combine will start in gear if normal circuit is bypassed. Start switch is located on right side of steering column. Key positions are:
First Position (O) .............................................................................. Off Second Position (I) ........................................................... Accessories Third Position (II) ............................................... Accessories and Run Fourth Position (III) ....................................................................... Start

When released, it will return to run or third position. If engine will not crank, check for: Multi-function lever in neutral Separator OFF Header OFF Auger swing switch in neutral Unloading auger OFF

ADecal

OUO6075,0001874 1922JUN011/1

45-6

101801

PN=212

ZX018660

UN26NOV99

The decal (A) on the storage box lid shows engine starting information.

H68449

UN06JUN01

Turn key to the fourth position to start. All lights on the warning display panel will come on.

Operating the Engine


Safety Rules for Starting Engine
CAUTION: Before starting engine, make sure everyone is clear of combine. Sound horn to warn other persons. Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open doors to get outside air into the area.

OUO6075,000011E 1901DEC001/1

50-1

101801

PN=213

Operating the Engine

Starting the Engine


CAUTION: Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. If the combine can be started with any of these switches on (B, C, D, E), the starting system needs diagnosing. See your John Deere dealer. 1. Make sure that battery main switch (A) is in ON position.
D
E

Battery Main Switch Shown (8.1 Liter Engine)

2. Move multi-function lever (B) to neutral. 3. Place orange engine speed control switch (C) in slow idle position.
UN07JUN01

4. Turn yellow header switch (D) and separator switch (E) off.
ABattery Main Switch (On) BMulti-function Lever CEngine Speed Control Switch DHeader Switch ESeparator Switch

Continued on next page

OUO6075,00018E9 1928JUN011/4

50-2

PN=214

H68484
101801

H67695

UN26APR01

Operating the Engine

CAUTION: Sound horn before starting engine to clear people away from combine. To avoid the possibility of personal injury or death, start the engine ONLY from the operator seat. Do not start engine by shorting across starter terminals. Combine will start in gear if normal circuit is bypassed.

5. Sound horn. Turn the key switch (B) to the on position. The buzzer will sound once due to low oil pressure. Start switch is located on right-side of steering column. Key positions are:
Key Positions
First Position
Second Position
Third Position
Fourth Position
UN16MAY01

Off
Accessories
Accessories and Run
Start

ADecal BStart Switch

Continued on next page

OUO6075,00018E9 1928JUN012/4

50-3

101801

PN=215

H68025

H54620

NOTE: Decal (A) on the storage box lid show engine starting information.

UN22JUN99

Operating the Engine


6. Turn the key switch to ignition position. Engine hydro charge pressure warning light (A), main gearcase pressure (B), engine oil pressure warning light (C) and parking brake indicator light (D) will come on if the park brake has been applied and the buzzer will sound one short pulse. If amber voltage light (E) comes on, this shows that battery voltage is low and combine may not start. IMPORTANT: To prevent starter damage, do not operate starter for more than 30 seconds at a time. If engine does not start, wait at least two minutes before trying again. 7. Turn key switch clockwise to start. All lights on the warning display panel will come on. Release key when engine starts. After engine starts, let it run at low idle for five minutes to warm the oil. After the engine starts, all lights except the park brake must be out. If any other lights stay on, stop the engine and correct.

A
D

4/4

3/4

B
C

AHydro Charge Pressure BMain Gearcase Pressure CEngine Oil Pressure DParking Brake EAmber Voltage Light

Continued on next page

OUO6075,00018E9 1928JUN013/4

50-4

101801

PN=216

H68035

UN31MAY01

Operating the Engine


NOTE: If Stop Engine Code (1) is displayed - The Triple Display tachometer will stop normal function and the DTC will be displayed. This indicates a problem that requires the combine be stopped, the engine turned off immediately and the problem corrected. The Triple Display Tachometer will show the DTC until the problem is resolved. If the problem cannot be resolved, see your John Deere dealer.
A

4/4

3/4

Amber light (A) will momentarily come on if the batteries are in a low charged state and will stay on if the combine electrical system voltage drops below 10 volts.
8. For turbocharger lubrication, run engine at low idle for a few minutes before applying a load to the engine.

AAmber Voltage Light

OUO6075,00018E9 1928JUN014/4

Warming up Engine
After engine starts, let it run at low idle for a few minutes to warm the oil before applying a load to the engine. All lights except the park brake must be out. If any other lights stay on, stop the engine and correct.

NOTE: If Stop Engine Code (1) is displayed - The Triple Display tachometer will stop normal function and the DTC will be displayed. This indicates a problem that requires the combine be stopped, the engine turned off immediately and the problem corrected. The Triple Display Tachometer will show the DTC until the problem is resolved. If the problem cannot be resolved, see your John Deere dealer.

HX,AG,SF6899 1905MAY991/1

50-5

101801

PN=217

H68036

UN31MAY01

Operating the Engine

Breaking-In Engine
The engine is ready for normal operation. However, extra care during the first 100 hours of operation will result in more satisfactory long-term engine performance and life. DO NOT exceed 100 hours of operation with break-in oil. 1. This engine is factory filled with John Deere Engine Break-in Oil. Operate the engine at heavy loads with minimal idling during the break-in period. 2. If the engine has significant operating time at idle, constant speeds, and/or light load usage, or makeup oil is required in the first 100 hour period, a longer break-in period may be required. In these situations, an additional 100 hour break-in period is recommended using a new change of John Deere Engine Break-in Oil and a new John Deere oil filter. IMPORTANT: DO NOT add makeup oil until the oil level is BELOW the ADD mark on dipstick. John Deere Engine Break-in Oil should be used to make up any oil consumed during the break-in period. DO NOT use PLUS-50 Engine Oil during break-in period of a new engine or engine that has had a major overhaul. PLUS-50 oil will not allow a new or overhauled engine to properly wear during this break-in period. 3. Check engine oil level more frequently during engine break-in period. If oil must be added during this period, John Deere Engine Break-In Oil is preferred. IMPORTANT: DO NOT fill above the FULL mark. Oil levels anywhere within the cross hatch marks are considered in the acceptable operating range. 4. During the first 20 hours, avoid prolonged periods of engine idling or sustained maximum load operation. If engine will idle longer than 5 minutes, stop engine. 5. After the first 100 hours maximum, change engine oil and replace engine oil filter. Fill crankcase with seasonal viscosity grade oil.

NOTE: Some increase in oil consumption may be expected when low viscosity oils are used. Check oil levels more frequently. If air temperature is below -10 degrees centigrade (14 degrees Fahrenheit) use an engine block heater.

PLUS-50 is a trademark of Deere & Company.

OUO6075,000018F 1904DEC001/4

The temperature gauge needle should read in the black zone. If needle moves into red/orange zone indicating 115C (240F), stop engine and check problem immediately.
UN04MAR99 H52262

Continued on next page

OUO6075,000018F 1904DEC002/4
101801

50-6

PN=218

Operating the Engine


Check engine oil level at dipstick (A) periodically. Do not operate engine when oil level is below low mark on dipstick.

NOTE: The oil should be checked with dipstick screwed all the way into the holder.
Remove dipstick and check oil level. Oil level should be between the ADD and the top of the cross-hatch area on dipstick. If oil level is below the ADD mark, add oil as needed. (See Fuel and Lubricants for oil recommendations). Watch for leaks. Do not operate engine with oil level below the ADD mark.
ADipstick
UN09APR01

OUO6075,000018F 1904DEC003/4

Check coolant level periodically. Watch for signs of leaks. Pour coolant into recovery tank to the COLD mark. Until you become familiar with the sound and feel of your combine, be extra alert.
UN19FEB99

OUO6075,000018F 1904DEC004/4

50-7

101801

PN=219

H54080

H59768

UN31AUG99

H67106

Operating the Engine

Break-In Check First 100 Hours


Perform daily or 10 hour service (See Lubrication and Maintenance section).
4/4

Watch engine temperature (A) and engine oil pressure (B). Check engine oil level (if needed, add John Deere Break-In Oil) and coolant level frequently and watch for any signs of leaks. Check engine air intake system hoses and clamps for tightness. Until you become familiar with the sound and feel of your combine, be extra alert.
AEngine Temperature BEngine Oil Pressure

3/4

OUO6075,00018EA 1928JUN011/1

Break-In Check After 100 Hours


Drain crankcase oil (A), change filter (B) and refill. (See Lubrication and Maintenance section). Change oil every 250 hours when using all other oils. Change oil every 375 hours, or once a season when using TORQ-GARD SUPREME or John Deere PLUS-50. IMPORTANT: If diesel fuel sulfur content exceeds 0.5 percent, change oil every 100 hours.
ACrankcase Oil BFilter

TORQ-GARD SUPREME is a trademark of Deere & Company. PLUS-50 is a trademark of Deere & Company.

HX,STSOE,P 1922JUL991/1

50-8

101801

PN=220

H67113

UN02APR01

H67112

UN02APR01

H68037

UN31MAY01

Operating the Engine

Hot Weather Operation


CAUTION: Coolant conditioner contains alkali. Avoid contact with eyes. Do not take internally. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. Call a physician. Keep out of reach of children. The cooling system must be clean and in good condition for operation. Loss of pressure results in over heating and loss of coolant. Check for: recovery tank coolant level plugged radiator leaking hoses broken fan belt or rotary screen belt engine fan should be at high speed

Leave antifreeze in cooling system all year around. If coolant is lost or drained, it must be replaced with the correct coolant and conditioner (See the recommendations given in Fuels and Lubricants in this manual). To prevent mineral deposits, do not use hard water. The use of Liquid Coolant Conditioner is recommended to protect against engine and cooling system wear. Add .9L (one quart) to radiator when coolant is changed.

OUO6075,0000076 1917NOV001/1

50-9

101801

PN=221

RG4690

The combine is shipped from the factory with permanent type 50/50 ethylene glycol antifreeze in the cooling system.

UN14DEC88

H54080

UN19FEB99

Operating the Engine

Cold Weather Operation


Use winter grade fuel. Fill tank at the end of each day to prevent condensation. Fuel tank cap (A) is not vented. The combine is shipped from the factory with 50/50 permanent type ethylene glycol antifreeze mix in the cooling system. Leave antifreeze in cooling system all year around. If coolant is lost or drained, it must be replaced with the correct coolant and conditioner (See the recommendations given in Fuels and Lubricants section in this manual). After adding antifreeze, turn heater on and run engine until it reaches operating temperature. This mixes the solution and circulates it through the system. IMPORTANT: Do not try to drain cooling system to protect against freezing. The heater does not drain completely, so freeze damage might result. When the temperature drops below freezing, keep batteries fully charged. Discharged batteries will freeze. In freezing weather, do not add water to batteries unless engine is to be run for 30 minutes or more or batteries are charged after water is added. Fill optional windshield washer reservoir with automotive washer solution.
UN26APR01

AFuel Tank Cap

OUO6075,00018EB 1928JUN011/1

50-10

101801

PN=222

H67698

Operating the Engine

Starting the Engine by Means of a Booster Battery


In very severe cold weather it may be necessary to connect an additional 12-volt battery in parallel with the combines batteries. CAUTION: Gas given off by batteries is explosive. Avoid sparks or open flames near the batteries. Make sure batteries are properly connected (ground cable to negative pole and starter cable to positive pole). IMPORTANT: Reversed polarity between the battery and alternator may result in severe damage to the electrical system. Always connect ground cable to negative pole last.
UN23AUG88

ZX,OMCTS 012147 1901SEP981/1

50-11

101801

PN=223

TS204

Operating the Engine

Stopping the Engine


1. Lower header or reel to the ground. If equipped with optional reel fore/aft, move reel all the way forward.
UN04MAR99

2. Move multi-function lever (A) to neutral and stop header (B) and separator (C). IMPORTANT: Cooling of turbocharger and some engine parts is provided by engine oil. Stopping a hot engine might cause damage to these parts. 3. Before stopping engine that has been operating at working load, idle at least one minute to cool turbocharger. CAUTION: Remove key from switch and set parking brake before leaving the combine. 4. Turn key and all other switches off.
AMulti-function Lever BHeader Switch CSeparator Switch

HX,AG,SF6900 1924SEP991/1

Stalling of Engine
IMPORTANT: If engine stalls at operating temperature, restart it immediately to prevent overheating of certain engine parts. Before finally shutting off the engine, run at slow idle for 1-2 minutes.

ZX,OMCTS 012149 1901SEP981/1

50-12

101801

PN=224

H61169

UN04OCT99

H52673

Driving and Transporting the Combine


Starting the Engine
CAUTION: Sound horn before starting engine to clear people away from the combine. Sound horn and start engine.
UN03APR95

OUO6075,00018EC 1928JUN011/1

Steering and Driving


CAUTION: Combine swings out when changing direction. Take care on bends. The steering wheels are located at the rear of the combine. Therefore, familiarize yourself with the different steering characteristics.

OUO6075,0001979 1925JUL011/1

Manual Parking Brake


IMPORTANT: The combine is equipped with manual engage and disengage parking brake pedals. Be certain to engage the parking brake when engine is running and combine is parked and before leaving the combine with the engine turned off. Press pedal (A) to engage the parking brake and pedal (B) to disengage the parking brake.
APedal (Engage) BPedal (Disengage)

OUO6075,0000053 1924JAN011/1

55-1

101801

PN=225

H60931

UN04OCT99

H69423

UN26JUL01

ZX002403

Driving and Transporting the Combine

Brake Pedals
Leave brake pedals (A) unlocked for field use. Lock brake pedals together with lock (B) for transporting.
APedals BLock (Transport)

OUO6075,00016E7 1918MAY011/1

Engaging a Gear
Engage 3rd gear for road travel. For field operation: Select a gear according to working conditions (preferably 2nd gear). Do not use 3rd gear unless four-wheel drive is engaged.
UN26JUL01

3 2 N

OUO6075,000197A 1925JUL011/1

Road Safety Switch


IMPORTANT: During road travel, road safety switch must be in position (I) (pressed). Thus all hydraulic functions with the exception of the steering system are shut off. Move header, unloading auger and grain tank covers to their transport positions.
IRoad Position
UN07JUN01

OUO6075,00018ED 1928JUN011/1

55-2

101801

PN=226

H68485

H69424

H68175

UN22MAY01

Driving and Transporting the Combine

Adjusting Engine Speed


Press engine speed switch (A) for maximum engine speed.
ASpeed Switch

OUO6075,00018EE 1928JUN011/1

Raising Header
Raise header to highest position with header switch (A).
A
AHeader Switch
UN07JUN01

OUO6075,00018EF 1928JUN011/1

Forward and Reverse Travel


CAUTION: Always adapt ground speed of combine to road or field conditions. Forward travel (I) Slowly push ground speed drive lever from Neutral to Forward (I). Reverse travel (II) Slowly pull ground speed drive lever from Neutral to Reverse (II).
UN07JUN01

H68488

OUO6075,00018F0 1928JUN011/1

55-3

PN=227

H68489
101801

H68487

UN07JUN01

Driving and Transporting the Combine

Reverse Travel Alarm


If the ground speed drive lever is moved to the rear (reverse travel) while the engine is running, signal sending unit (A) emits an acoustic alarm signal.
AAlarm
UN02DEC99

OUO6075,000007F 1917NOV001/1

Choosing Correct Ground Speed


Never select a speed lower than the minimum speed for the individual speed range.
UN26NOV99

It is always better to choose a lower speed range as this will give a more efficient hydrostatic drive performance.

OUO6075,000030E 1904JAN011/1

55-4

101801

PN=228

ZX019050

ZX019046

Driving and Transporting the Combine

Avoid Overheating of Hydrostatic System


When hydrostatic oil temperature is too high, yellow light comes on and at the same time the buzzer will be activated (continuous warning signal). In this case select a lower speed range, giving more efficient hydrostatic system operation and reducing the oil temperature. IMPORTANT: If the ground speed drive stalls, never wait more than 5 seconds before shifting the ground speed drive lever back to Neutral. Then select a lower speed range.
UN04MAR99 H52370

NOTE: Drive wheel torque depends on oil pressure in hydrostatic system. If the pressure requirement exceeds the pressure in the hydrostatic system, a relief valve will open and the combine will stop. As soon as the pressure requirement drops (i.e. a lower speed range is selected), the combine will travel normally again.

AG,OUZXMAY,259 1919NOV991/1

Transport Information
CAUTION: To reduce risk of electrical shock, no portion of machine should exceed a height of 4 m (13 ft 1 in.). Check local governmental regulations regarding driving or towing equipment on public roads. Use auxiliary lights and devices available from your John Deere dealer to warn other road users. The combine harvester can be transported on a flat bed truck or by towing. When towing, place the gear shift lever in neutral. Do not exceed a maximum speed of 25 km/h (15 mph). Do not exceed a maximum speed of 20 km/h (12 mph) German combines only.

OUO6075,0001575 1928FEB011/1

55-5

101801

PN=229

Driving and Transporting the Combine

Transporting Under Own Power


CAUTION: For safety reasons, always couple brake pedals by means of pedal coupler (A) when driving on public roads. This ensures the brakes are actuated together. For general information on driving, see this Section. Remove header, if overall width exceeds the legal limits (for details of removal, see relevant operators manual). Move the feeder house to transport position.
APedal Coupler

Empty the grain tank. Swing in the unloading auger.

OUO6075,000039C 1911JAN011/2

Pivot and secure the access ladder in full forward position to reduce combine width. Use lever (A) to unlock ladder and swing to the full forward position. Switch on the lights, if necessary. Lower radio antenna. Close grain tank cover.
ALever
UN18APR01

OUO6075,000039C 1911JAN012/2

55-6

101801

PN=230

H67583

ZX000512

UN03APR95

Driving and Transporting the Combine

Four Wheel Drive (Orange) (Optional)


IMPORTANT: To prevent damage to the hydrostatic system, do not switch 4-Wheel Drive on or off while driving combine in third gear (road gear) at maximum travel speed. Reduce speed to less than 1/2 of maximum. Turn 4-wheel drive off before going down a steep grade. When driving the combine in conditions which cause high pressures in the hydrostatic system and the combine slows down or stops, move multi-function lever to neutral and shift to a lower gear. It is ok to switch between low (turtle) and high (rabbit) settings on the GO while harvesting. Switch (A) control the 2-speed 4-wheel drive system. Press either switch once to engage and once to turn off. A lighted indicator above each switch is on when the drive is engaged. Press the bottom switch (turtle) when more traction is required or the top switch (rabbit) when higher speeds are required. CAUTION: Ground speed will increase when disengaging four-wheel drive and will decrease when engaging four-wheel drive.
A4-Wheel Drive Control Switch

A
UN21DEC00

NOTE: For best overall performance it is recommended that the 2-speed 4-wheel drive be left in the low (turtle) speed mode. This will allow the machine to operate at maximum torque capacity.
It is NORMAL for front wheels to lose traction and spin out before the rear wheels in most conditions. In extremely muddy conditions, it may be necessary to apply both brakes momentarily to increase hydrostatic pressure to the 4-wheel drive motors. If rear wheels are spinning excessively shift from 2nd gear to 1st gear.

Continued on next page

OUO6075,00018F1 1928JUN011/2
101801

55-7

H65398

PN=231

Driving and Transporting the Combine


When the drive is engaged, these approximate reductions in ground speed occur: First Gear: 20% Second Gear: 30% Third Gear: 50%

OUO6075,00018F1 1928JUN012/2

Towing the Combine


CAUTION: Do not tow combine with wire rope. If rope breaks, the whipping action could cause bodily injury. Do not tow the combine except in an emergency for a short distance. The combine should not be towed any faster than 8 km/h (5 mph). To tow the combine, proceed as follows: Empty grain tank and remove header. Swing auger back. Fold grain tank covers. Swing ladder to front of tire and fold down radio antenna. Disengage park brake. CAUTION: Do not remove couplers. When couplers are removed, brakes are disabled. Place gearshift and multi-function lever in neutral. IMPORTANT: When towed in this manner, the transmission lube pump is not working and exceeding 8 km/h (5 mph) could damage the transmission. Tow in the forward direction by attaching a chain around the main axle. Be certain the chain will not damage any hydraulic lines. Have a driver in the operators seat to steer and brake the combine.
UN16JUN95

Continued on next page

OUO6075,00017FA 1914JUN011/2
101801

55-8

PN=232

ZX002420

Driving and Transporting the Combine

CAUTION: Prevent collisions between other road users, slow moving tractors with attachments or towed equipment and self-propelled machines on public roads. Frequently check for traffic from the rear, especially in turns, and use turn signal lights. Use headlights, flashing warning lights, and turn signals day and night. Follow local regulations for equipment lighting and marking. Keep good lighting and markings visible, clean, and in good working order. Replace or repair lighting and markings that has been damaged or lost. An implement safety lighting kit is available from your John Deere dealer. Turn on warning lights, unless prohibited by law. Travel at a safe and reasonable speed, not to exceed 8 km/h (5 mph).

OUO6075,00017FA 1914JUN012/2

Attaching Machine Safely


CAUTION: Help prevent personal injury caused by unexpected movement of the machine. Engage parking brake, shut off engine and remove key before working around hitch.

OUO6075,00015A6 1921MAR011/1

55-9

101801

PN=233

TS230

UN24MAY89

Driving and Transporting the Combine

Trailer Hitch
CAUTION: Shut off engine, remove key, and set parking brake before hooking up trailer.
UN31MAY01

Attach trailer to hitch and secure with trailer hitch pin (B). Connect plug for trailer lights to socket (A).
ASocket BTrailer Hitch Pin

OUO6075,0001770 1931MAY011/1

Transporting Combine on a Trailer


1. Empty grain tank and remove header. 2. To reduce overall height, swing unloading auger back, close grain tank covers (A) and (B).
AGrain Tank Covers BGrain Tank Covers
UN14MAY01

OUO6075,0001786 1904JUN011/6

3. Adjust the rear axle to the smallest position. It is also required to attach steering cylinder (both sides) to position (E). 4. Drive combine on trailer and put multifunction lever in neutral. 5. Fold radio antenna down.
EPosition
UN18JUL01

Continued on next page

OUO6075,0001786 1904JUN012/6

55-10

101801

PN=234

H69334

H67976

H68369

Driving and Transporting the Combine


6. Tape exhaust pipe cap (A) closed to prevent damage to turbocharger. 7. Wire down cover over engine.
UN15DEC98

8. Swing rear warning lamps forward.


AExhaust Pipe Cap

OUO6075,0001786 1904JUN013/6

9. Wire down ladder extension and platform (A).


ALadder Extension and Platform

Continued on next page

OUO6075,0001786 1904JUN014/6

55-11

101801

PN=235

H61818

UN11NOV99

H42609A

Driving and Transporting the Combine


10. Make sure that pin (A) is installed through locking plate (B) and retained with spring pin at front corner of right-hand gull wing door and door latch (C) is fully engaged. 11. Wire down door at latch (C).
APin BLocking Plate CDoor Latch
UN25JAN01

Continued on next page

OUO6075,0001786 1904JUN015/6

55-12

101801

PN=236

H65939

UN25JAN01

H68502

UN05JUN01

H65929

Driving and Transporting the Combine


12. Make sure pins (A) are installed through locking plates (B) and retained with spring pins at front and rear corners of left-hand gull wing doors and door latches (C) is fully engaged. 13. Wire down door at latches (C). IMPORTANT: Fasten combine to trailer with chains.
APins BLocking Plates CDoor Latches
UN25JAN01

Left-Hand Front Corner Pin

OUO6075,0001786 1904JUN016/6

Unloading Auger Transport Protection


Attach cap screw and washer (A) to unloading auger IMPORTANT: Remove cap screw and washer (A) for field operation.
ACap Screw and Washer
UN04JUN01

OUO6075,0001771 1931MAY011/1

55-13

101801

PN=237

H68371

H65938

UN25JAN01

H68501

UN04JUN01

H65931

Wheels, Axles and Additional Weights


Service Tires Safely
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 hose long enough to allow you to stand to one side 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.

DX,RIM 1924AUG901/1

Tire Maintenance
Check tires daily for damage and noticeably low pressure. Long life and satisfactory performance depend on proper tire inflation. At least every 50 hours of operation, check tire pressure. If tires contain liquid ballast, use a special air-water gauge and measure with valve stem at bottom. A small puncture in a tubeless tire can be temporarily repaired without dismounting the tire, thus avoiding down time during a busy season. IMPORTANT: A permanent, inside-out repair should be made as soon as possible to prevent any further tire damage. Have cuts or tears repaired as soon as possible, or change tire. Protect tires from unnecessary exposure to sunlight, petroleum products and chemicals. Drive carefully. Try to avoid rocks and sharp objects.

OUO6075,0001752 1930MAY011/1

60-1

101801

PN=238

TS211

UN23AUG88

Wheels, Axles and Additional Weights

Rear Wheel Bolt Torque


Each time a rear wheel is removed, torque wheel bolts to specification. Then, re-torque wheel bolts after one hour of operation.
Specification Wheel Bolts (Non-Powered Axles)Torque (Dry).................................................................... 260 Nm (192 lb-ft) Wheel Bolts (Powered Axles) Torque (Dry) ................................................................ 200 Nm + 1/4 turn (150 lb-ft + 1/4 turn)
UN25JAN01

NOTE: Mount rear tires with the offset in and valve stems to the outside.

OUO6075,00019D9 1909AUG011/1

Drive Wheel Bolt Torque


IMPORTANT: Wheel bolts must be clean and free of lube before installing. Torque value is for clean, dry bolt. Lubricating reduces friction and overloads the bolts. 1. Each time a drive wheel is removed, torque wheel bolts to specification without using a torque multiplier. Tighten bolts in a criss/cross pattern.
Specification Wheel BoltsTorque .................................................. 200 Nm + 1/4 turn (150 lb-ft + 1/4 turn)
UN11OCT88

2. Use a 4 to 1 torque multiplier and turn bolt head 1/4 turn (ratchet or torque wrench will make a full turn). Pull multiplier lever against inside of wheel when tightening.

NOTE: If the combine is equipped with 100 mm (4 in.) wheel spacers, turn each bolt head 1/2 turn (ratchet or torque wrench will make two full turns.

AWheel Bolt BSocket, 30 mm (3/4 In. Drive) C4 to 1 Multiplier 1356 Nm (1000 lb-ft capacity) (13 mm (1/2 in.) Input Drive, 19 mm (3/4 in.) Output Drive) DLong Extension, 13 mm (1/2 in.) Drive x 457 mm (18 in.) ETorque Wrench FWheel

AG,OUO1035,1616 1924JAN001/1

60-2

101801

PN=239

H39319

H65941

Wheels, Axles and Additional Weights

Mounting Tires
CAUTION: Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your John Deere dealer or a qualified tire repair service. When seating tire beads on rims, never exceed maximum inflation pressures specified by tire manufacturers for mounting tires. Inflation beyond this maximum pressure may break the bead, or even the rim, with dangerous explosive force. If both beads are not seated when the maximum recommended pressure is reached, deflate, reposition tire, relubricate bead and reinflate. Detailed agricultural tire mounting instructions, including the necessary safety precautions, are available from your local tire manufacturer agents. IMPORTANT: Never operate combine with tires at shipping pressure. Keep valve caps screwed down on valve stems to prevent foreign material from accumulating in the valve core. Check tire pressure frequently, referring to tire pressure charts. Required pressure may vary as load changes with the installation of different header units.

ZX,OMCTS 012168 1901SEP981/1

60-3

101801

PN=240

Z20924

UN15AUG94

Wheels, Axles and Additional Weights

Changing Tires
IMPORTANT: When changing drive wheels, tire radius may also change. If so, the control unit C03 must be adjusted to the new tire radius. See your John Deere dealer for further information.

AG,OUZXMAY,265 1919NOV991/1

Using Liquid Weight


CAUTION: Installing liquid weight (ballast) requires special equipment and training. Have the job done by your John Deere dealer or a tire service store. IMPORTANT: Cover rim completely with solution to avoid corrosion, but NEVER fill any tire more than 90 percent full. More solution would leave too little air space to absorb shocks. Damage to tire could occur. A solution of water and calcium chloride provides safe, economical ballast. A tube should be used to prevent rusting of the rims. If used properly, it will not damage tires, tubes or rims.

OUO6075,0001753 1930MAY011/1

Drive Wheel Starter Stud


If a wheel is removed, thread rim starter stud into axle, then install wheel. This stud can also be used for duals.

NOTE: Wheel bolts are M20 x 1.5.


UN11OCT88

AG,OUO1035,1615 1924JAN001/1

60-4

101801

PN=241

H39318

H65942

UN25JAN01

Wheels, Axles and Additional Weights

Wheel Offset
CAUTION: Avoid serious injury or death resulting from final drive failure and loss of drive wheel during transport or field operation. Do not exceed maximum wheel offset. IMPORTANT: Use only John Deere supplied wheels, tires and spacers. Use of non-John Deere components not meeting John Deere specification will void John Deere warranty. Do not use clamp-on style duals. They do not meet John Deere specification. Wheel offset distance severely affects life of final drive parts. When installing drive wheels, ensure that offset dimension (A) measured from spindle surface (B) to centerline (C or D) is within specification.
Maximum Wheel OffsetSpecification Single WheelDistance ............................................ 114.3 mm (4-1/2 in.) Dual WheelsDistance..................................................... 50.8 mm (2 in.)

B
UN30OCT00

Single Wheel

Dual Wheels

OUO6035,000004A 1917OCT001/1

60-5

101801

PN=242

H65048

UN30OCT00

ADimension BSpindle Surface CTire Centerline DCenterline of Duals

H65047

Wheels, Axles and Additional Weights

Jacking Locations
CAUTION: Always empty grain tank before jacking up the combine.
UN22JUN99

Do not jack combine at any other location than those with a jack pocket.

Front Jacking Location

Rear Jacking Location


AG,OUZXMAY,393 1928NOV991/1

60-6

101801

PN=243

H58396

UN22JUN99

H58395

Harvesting Hints
Choice of Harvesting Time
This combine can be adjusted to harvest almost any crop under most conditions. Become familiar with the following before beginning: The crop must be ready to thresh. Moisture content must not be too high and straw must not be too green. Grain with 12 percent moisture or less, and corn with 14 percent moisture or less, is considered dry enough for safe storage.
UN11OCT88

OUO1035,000024D 1920SEP001/1

Harvesting Tips
Adjust the combine for the crop being harvested and the field condition.
UN05MAR99

Use a ground speed that will not overload the combine. The engine must be at full rpm to keep the separator at full speed. Use ground speed for slower travel or shift to a lower gear, but do not slow down the engine. If the concave is set too close for the crop being harvested, the straw will be excessively ground up and more horsepower will be required to thresh the crop. If the concave is set too wide, the crop will not be completely threshed. After the concave is properly adjusted, the cylinder speed is then adjusted to achieve maximum threshing with the least crop damage. If crop damage does occur, do not widen the concave clearance. Instead, reduce the cylinder speed. Concave spacing in these crops has very little effect on seed damage. Crops, such as edible beans and peas, are easily cracked and can require the use of a special slow speed cylinder drive. When combining edible beans and peas, keep the combine full to provide enough material to cushion the crop against cracking.

Continued on next page

OUO6075,0001985 1926JUL011/2
101801

65-1

PN=244

H52690

H39280

Harvesting Hints
Adjust precleaner openings with tool (A) to pass the grain or seed to the lower sieve in the first two-thirds of the chaffer without admitting too much coarse material. Adjust the precleaner to the minimum setting for all crops except corn. Use as much air as possible without blowing over clean grain and seed. Heavy crops require more air than light seed crops. When using a cutting platform, cut the crop as high as possible without loss of low heads. Adjust reel position and speed for even feeding. Keep the cutterbar in register and the guards in alignment for clean cutting. When harvesting corn, keep the corn head only as low as necessary for ears. Keep it centered in the rows to prevent ear loss. When harvesting soybeans with a row-crop head, keep the header as low as possible. When harvesting crops such as milo or sunflowers, operate the header just low enough to cut the heads from the stalks.
UN14MAY01

APrecleaner Adjustment Tool

OUO6075,0001985 1926JUL012/2

65-2

101801

PN=245

H67978

Automatic Combine Adjust System


Automatic Combine Adjust System
This system provides the operator with factory recommended settings for the machine and allows the operator to enter a custom setting for various crops. This system automatically adjusts to these stored settings: threshing speed, fan speed, and concave clearance. Crops names can be displayed in the following languages: English German French Italian Spanish Swedish Dutch Norwegian Hungarian Czech Polish Romanian Estonian Latvian Lithuanian

OUO6075,00003B9 1911JAN011/1

70-1

101801

PN=246

Automatic Combine Adjust System

Crops
The following crops are preloaded into the automatic combine adjust system. The operator may enter one modified crop for each of the factory installed crops. An additional five crops may be added as custom crops. They will be displayed as CROP 1CROP 5.
Crop
Wheat (Normal)
Wheat (Difficult)
Barley
BARLEY (Difficult)
Rye
Oats
Canloa
Grass Seed
Linseed
Peas
Soybeans
Sunflower
Corn (dry)
Corn (wet)
Rice
Lupin

Display (English)
WHEAT1
WHTDF1
BARLY1
BRLDF1
RYE1
OATS1
CANOL1
GRASS1
LINSD1
PEAS1
SOYBN1
SNFLR1
CORND1
CORNW1
RICE1
LUPIN

Threshing Speed
900
850
700
700
850
950
600
800
900
380
550
350
380
550
800
500

Cleaning Fan Speed


1050
1050
950
950
1100
1050
700
700
900
1100
1000
1000
1200
1200
1050
1100

Concave Clearance
10
3
7
7
10
12
30
5
6
25
30
45
35
35
15
25

Chaffer Position
16
19
19
19
16
16
10
8
12
16
16
12
16
16
16
16

Sieve Position
6
6
6
6
6
6
5
4
3
10
10
6
11
11
6
6

Precleaner Position
3
3
3
3
3
3
3
3
3
3
3
3
10
10
3
0

OUO6075,00018F3 1928JUN011/1

70-2

101801

PN=247

Automatic Combine Adjust System

Automatic Combine Adjust Display Settings


NOTE: The display below will be shown when displaying factory crop one settings (WHEAT1, WHTDF1, etc). The sieve indicator bar (B), chaffer adjusting bar (A), precleaner adjusting bar (C) and the preset number (D) will be displayed 10 seconds before disappearing.
After 10 seconds have elapsed, the numbers displayed will switch from set points to actual values.
C AChaffer Indicator Bar BSieve Indicator Bar CPrecleaner Adjusting Bar DPreset Number

OUO6075,00018F4 1928JUN011/1

70-3

H68821
101801

PN=248

UN01AUG01

Automatic Combine Adjust System

F
G

Adjusting Predefined Settings


NOTE: Actual adjustments of threshing speed should take less than 50 seconds. If threshing speed is not reached in the allotted time an error code will appear. Actual adjustments of concave clearance should take less than 30 seconds. If concave clearance is not reached in the allotted time an error code will appear. Actual adjustments of fan speed should take less than 130 seconds. If fan speed is not reached in the allotted time an error code will appear.
1. To scroll through the different crop settings push the up or down arrows (A).

3. Press the auto button (B). 4. Crop name (C) will be displayed as actual positions for threshing speed (E), fan speed (F), concave clearance (G) are being adjusted. The icon will flash until all positions are reached or adjusted manually. 5. Pressing the back button will stop the automatic adjustment.
B

AUp or Down Arrows BAuto Button CCrop Name DCrop Setting EThreshing Speed FFan Speed GConcave Clearance

OUO6075,000038E 1910JAN011/1

70-4

101801

PN=249

H65822

UN25APR01

2. To adjust to desired crop settings (D), the separator must be engaged, and engine at high idle.

Automatic Combine Adjust System

Factory Crop 2 (WHEAT 2) and Personal CROP1 CROP5 Setting Changes (Automatic Calibration)
NOTE: Factory crop will be displayed as WHEAT 2, etc. Personal crop settings will be displayed as CROP1CROP 5, or a specified name. Personalizing the threshing speed, concave clearance, and fan speed will not override the factory one settings, because the system will automatically default to factory two settings.
1. To save crop settings using automatic calibration, the header is engaged, separator is engaged, and engine is at high idle. 2. Press cal button (A).

A
UN16JAN01

3. The text display will alternate between the crop name (B) and EOC. 4. Press the enter button (D) to save the current settings to the selected crop.
D

5. Press the back button (C) to not save settings.


ACalibration Button BCrop Name CBack Button or Abort DEnter Button

OUO6075,000038F 1910JAN011/1

70-5

101801

PN=250

H65823

Automatic Combine Adjust System

Factory Crop 2 (WHEAT 2) and Personal CROP1 CROP5 Setting Changes (Manual Calibration)
NOTE: During harvest (separator engaged, header engaged, engine at high idle) the cal button must be pressed twice in consecutive order to begin manual calibration. Before harvesting pressing the cal button once will begin manual calibration.
1. Press cal button. Threshing speed (C) setting will flash.
C

NOTE: By holding the up or down arrow for more that four seconds the threshing speed will increase or decrease by increments of one hundred.
2. Press up or down arrow to increase or decrease threshing speed in increments of ten.
A

E
G

B
UN16JAN01

3. Press cal button. The concave clearance setting (D) will flash.

NOTE: By pressing and holding the up or down arrow for more than four seconds the concave clearance will increase or decrease by increments of ten.
4. Press up or down arrow to increase or decrease concave clearance in increments of one. 5. Press cal button. Fan speed setting (E) will flash.
AUp or Down Arrow BCalibration Button CThreshing Speed DConcave Clearance EFan Speed FEnter Button GBack Button or Abort

NOTE: By holding the up or down arrow for more that four seconds the fan speed will increase or decrease by increments of one hundred. NOTE: If calibrating the Factory 2 Crop settings pressing the cal button will advance to the threshing speed again, since the name cannot be changed.
6. Press up or down arrow to increase or decrease fan speed in increments of ten. 7. Press the cal button to move to the crop name settings. 8. The first character in the name will start to flash.

Continued on next page

OUO6075,0000391 1910JAN011/2
101801

70-6

PN=251

H65824

Automatic Combine Adjust System


9. Use the up or down arrow (A) to change to the desired letter. 10. To advance to the next letter in the name press the cal button (B). Repeat through all the characters. 11. Press the enter button (F) to end the calibration. The text will alternate between the name and EOC. 12. Press the enter button (F) again will save the calibration. 13. Press the back button (G) to exit without saving. The text will alternate between the name and abort, and the settings are not saved

OUO6075,0000391 1910JAN012/2

70-7

101801

PN=252

Crop Settings and Seed Loss Charts


Crop Settings
The following settings for various crops are for average conditions. Varying crop and field conditions may require slightly different settings.

Continued on next page

OUO6075,000168A 1930APR011/3

75-1

101801

PN=253

Crop Settings and Seed Loss Charts


NOTE: Some of these settings are on the card in the storage area under the arm rest.
Crops Cylinder Speed (RPM)
500-660

Cylinder to Concave Indicator


0

Cylinder Filler Plates


NA

Concave Rear Inserts


NA

Beater Grate

Fan Speed (RPM)


770

Precleaner Chaffer Setting

Sieve Setting

Extension Setting

Alfalfa

Up

3 mm (1/8 in.) Fixed Hole


Closed

12 mm (1/2) in.

3 mm (1/8) in. Fixed Hole


5-7 mm (3/16-5/16 in.)
10-12 mm (3/8-1/2 in.)

12 mm (1/2) in.

Barley (Feed and Malting)


Beans (Edible) and Black Eyed Peas
Beans (Soy)
Canola (Spring)
Canola (Winter)
Corn (Shelled)a,
b

600-850

0-15

Removed

Removed

Up

900-1000

18-20 mm (3/4-13/16 in.)


15-17 mm (5/8-11/16 in.)

18-20 mm (3/4-13/16 in.)


11-13 mm (7/16-1/2 in.)

160-180

18-38

Removed

Installed

Up

950-1050

Closed

300-480

14-38

Removed

Removed

Up

950-1000

Closed

15-17 mm (5/8-11/16 in.)


10 mm (3/8 in.)
9-11 mm (3/8-7/16 in.)
15-17 mm (5/8-11/16 in.)
15-17 mm (5/8-11/16 in.)
Removed
12 mm (1/2 in.)
6-10 mm (1/4-3/8 in.)

9-11 mm (3/8-7/16 in.)


5 mm (3/16 in.)
4-6 mm (3/16-1/4 in.)
10-12 mm (3/8-1/2 in.)
d

11-13 mm (5/8-1/2 in.)


10 mm (3/8 in.)
9-11 mm (3/8-7/16 in.)
9-11 mm (3/8-7/16 in.)
9-11 mm (3/8-7/16 in.)
Closed
12 mm (1/2 in.)
12-16 mm (1/2-5/8 in.)

380-550
450-500

0-38
20-38

Removed
Removed

Removed
Removed

Up
Up

700
800-900

Closed
Closed

(Dry Corn) 300-425

Installed

Installed

Up

1050-1100

7-9 mm (5/16-3/8 in.)


5-7 mm (3/16-5/16 in.)
Closed
Closed
Closed

Corn (Shelled)e,
b

(Wet Corn) 330


f

Installed

Installed

Up

1250-1300

10-12 mm (3/8-1/2 in.)


d

Corncob Mix
Flax
Grass Seeds
a
b
c

600-800
680-960
670-980

30-50
0-15
0-10

NA
NA
NA

NA
NA
NA

Up
Up
Up

900 and up
920
500-750

Removed
3 mm 1/8 in.)
3-6 mm (1/8-1/4 in.)

Hard/firm cob, set concave to 38-40 (full open)

Concave inserts installed

Before Setting concave, first determine average cob type for the field being harvested.
Never less than 6 mm (1/4 in.)

d
e
f

Rubbery/spongy cob, set concave to 50-55

Go up/down in 30 rpm increments

Continued on next page

OUO6075,000168A 1930APR012/3
101801

75-2

PN=254

Crop Settings and Seed Loss Charts


Crops Cylinder Speed (RPM)
550-760

Cylinder to Concave Indicator


15

Cylinder Filler Plates


NA

Concave Rear Inserts


NA

Beater Grate

Fan Speed (RPM)


900

Precleaner Chaffer Setting

Sieve Setting

Extension Setting

Guar (Cluster Beans)


Millet (Proso)
Mustard

Up

Closed

10 mm (3/8 in.)
10-13 mm (3/8-1/2 in.)
10 mm (3/8 in.)
15-17 mm (5/8-11/16 in.)
16 mm (5/8 in.)
15 mm (5/8 in.)
15-17 mm (5/8-11/16 in.)
15-17 mm (5/8-11/16 in.)
16 mm (5/8 in.)
16 mm (5/8 in.)
15-17 mm (5/8-11/16 in.)
11-13 mm (7/16-1/2 in.)
15-17 mm (5/8-11/16 in.)

3 mm (1/8 in.)
5 mm (3/16 in.)
3-6 mm (1/8-1/4 in.)
5-7 mm (3/16-5/16 in.)
8-10 mm (5/16-3/8 in.)
10 mm (3/8 in.)
5-7 mm (3/16-5/16 in.)
5-7 mm (3/16-5/16 in.)
6 mm (1/4 in.)
6 mm (1/4 in.)
5-7 mm (3/16-5/16 in.)
5-7 mm (3/16-5/16 in.)
5-7 mm (3/16-7/16 in.)

10 mm (3/8 in.)
10-13 mm (3/8-1/2 in.)
15 mm (5/8 in.)
15-17 mm (5/8-11/16 in.)
19 mm (3/4 in.)
19 mm (3/4 in.)
15-17 mm (5/8-11/16 in.)
15-17 mm (5/8-11/16 in.)
19 mm (3/4 in.)
19 mm (3/4 in.)
15-17 mm (5/8-11/16 in.)
11-13 mm (7/16-1/2 in.)
15-17 mm (5/8-11/16 in.)

500-550

15-20

NA

NA

Up

950

Closed

630-980

0-15

NA

NA

Up

750

Closed

Oats

600-850

Removed

Installed

Up

900-1000

Closed

Peas (Field)
Popcorn
Rice

240-470

15-35

NA

NA

Up

1100

Closed

300-520g
(Rasp Bar) 650-800
(Spike Tooth) 600-750
670-850
500-650
600-800

20-40
0-20

NA
Removed

NAh
Removed

Up
Up

1200-1300
1000-1100

3 turns
Closed

Rice

0-20

Removed

Removed

Up

1000-1100

Closed

Rye
Safflower
Sorghum

0-20
5-20
10-35

NA
NA
Removed

NA
NA
Removed

Up
Up
Up/Down

1000
1050
1050-1150

Closed
Closed
Closed

Sunflowers 300-350

45

Removed

Removed

Up

950-1050

Closed

Wheat

600-900

0-10

Removed

Removed

Up

1000-1100

Closed

g
h

Increase by 10 increments

Install rear concave inserts should unthreshed losses occur. Rear concave opening may become blocked by husks.

OUO6075,000168A 1930APR013/3

75-3

101801

PN=255

Crop Settings and Seed Loss Charts

Seed Loss Chart (Platforms)


The following seed loss chart shows the number of seeds that equal a 50 kg per hectare loss (bushel per acre). A few seeds behind the combine does not call for numerous adjustments.
PLATFORM MODEL
918
Combine
9540, 9640, 9560, 9580
9660, 9680
9540, 9640, 9560, 9580
9660, 9680
9540, 9640, 9560, 9580
9660, 9680
9540, 9640, 9560, 9580
9660, 9680
9540, 9640, 9560, 9580
9660, 9680
9540, 9640, 9560, 9580
9660, 9680
9540, 9640, 9560, 9580
9660, 9680

920

922

925

Crop
BARLEY
BARLEY
FLAX
FLAX
OATS
OATS
RYE
RYE
SORGHUM
SORGHUM
SOYBEAN
SOYBEAN
WHEAT
WHEAT

62 (68)
51 (57)
317 (408)
260 (340)
50 (36)
41 (30)
113 (145)
93 (121)
59 (76)
49 (63)
10 (14)
9 (12)
55 (76)
45 (63)

68 (76)
57 (63)
349 (454)
291 (378)
55 (41)
46 (34)
125 (161)
104 (134)
65 (85)
54 (71)
12 (16)
10 (13)
60 (84)
51 (70)

75 (76)
62 (69)
383 (498)
320 (415)
61 (45)
50 (37)
136 (177)
114 (147)
72 (94)
60 (78)
13 (17)
11 (14)
84 (92)
55 (77)

82 (91)
68 (76)
418 (544)
349 (453)
66 (49)
55 (41)
149 (194)
125 (162)
78 (102)
65 (85)
14 (19)
12 (16)
73 (101)
60 (84)

These figures are approximate and vary with seed size and variety. Seeds are gathered directly behind the separator without a straw spreader or straw chopper.

OUO6075,0001999 1931JUL011/1

75-4

101801

PN=256

Crop Settings and Seed Loss Charts

Soybean Loss Chart (Row-Crop Heads)


To determine soybean losses, operate the row-crop head in from the ends of the field and where the crop is typical of the entire field. Stop and back the combine (4.5 m) 15 ft. away from standing soybeans. Mark off an area from where drive tire tracks stop (A), 0.6 m (2 ft.) to point (B). Now mark off header width. Check this area (C) for losses. Soybean losses are determined by counting the number of beans in the plot for any or all of the following types of gathering losses. 1. Stubble Loss: Pods left attached to stalk stubble. 2. Uncut Stalk: Lodge or down stalks not gathered by the row-crop head. 3. Cut Stalk Loss: Stalks cut but lost in the gathering process. 4. Pods: Loose pods detached from stalks. 5. Shatter: Loose soybeans on the ground. Pre-harvest losses (loose soybeans and pods in the rows) are generally low and can be included in the total loss count.
TOTAL NUMBER OF SOYBEANS COUNTED IN PLOT FOR A ONE HECTARE (BUSHEL PER ACRE) LOSS
Row-Crop Head Model
454A
UN14MAR89

ATire Tracks BPoint CLoss Area

Row Spacing
914 mm (36 In.)
965 mm (38 In.)
1016 mm (40 In.)

Number of Soybeans
86
91
96
101
108
129
136
135
144

653A

711 mm (28 In.)


762 mm (30 In.)

654A

914 mm (36 In.)


965 mm (39 In.)

853A

711 mm (28 In.)


762 mm (30 In.)

The above soybean loss figures are based on approximately 2600 soybeans per lb. (0.45 kg).

HX,AG,SF6933 1920MAR901/1

75-5

101801

PN=257

H39605

Crop Settings and Seed Loss Charts

Combine and Corn Head Check List


NOTE: The following items must be checked and adjusted properly before attempting to use the set-up flow chart in this section.
Combine: Feeder house front drum in "corn" position. Feeder house conveyor drive on "small" sprocket. Feeder house conveyor chain tension is properly adjusted. Cylinder has full set of corn filler plates. Cylinder rasp bars are free of nicks and abrasions. New non-chrome bars require at least 50 hours use prior to harvesting high-moisture corn to smooth rough edges.

NOTE: Chrome rasp bars are not recommended unless free of sharp or rough edges, nicks and abrasions.
Concave is leveled and proportioned to cylinder. Full set of inserts installed in concave. Second concave curtain option is recommended. Full set of straw walker risers. All elevator chains are properly tensioned. All augers are free from nicks, cracks and sharp edges.

Corn Head: All points level and adjusted for field condition. Stalk rolls in good condition. Trash knives adjusted properly. All gathering chains set with lugs offset. Deck plates in good condition and adjusted properly. Cross auger adjusted "up" and "forward". Cross auger has full set of paddles in good condition. Row unit drive sprockets set for at least a 1:1 drive ratio. Cross auger drive has a "slow down" sprocket (standard equipment on 90 series corn heads [660101 - ]).

HX,AG,SF6934 1915APR981/1

75-6

101801

PN=258

Crop Settings and Seed Loss Charts

Corn Kernel Loss Chart


The following kernel loss chart shows the number of kernels that must be lost per square meter (foot) before a total of one bushel per hectare (acre) is lost. It also points out that a few kernels lost behind the combine does not call for numerous adjustments on the combine.
Corn Head Number Row Spacing Number of Rows 9540, 9640, 9560, 9580 9660, 9680

Kernels Per Square Meter (Foot) for One Bu. Loss Per Hectare (Acre)
443 711 mm (28)
762 mm (30)
493
444

4
4
4
4
4
4
4
4
5
5
5
6
6
6
6
6
6
8
8
8
8
8
12

4
4
4
5
5
5
5
5
6
6
6
6
6
6
7
8
8
8
8
8

5
5
5
4
5
5
7
7
7
6
7
7
8
9
10

762 mm (30)
914 mm (36)
965 mm (38)
1016 mm (40)

494

914 mm (36)
965 mm (38)

546
594

914 mm (36)
914 mm (36)
965 mm (38)

643

711 mm (28)
762 mm (30)

693
644 and 694

762 mm (30)
914 mm (36)
965 mm (38)

645
843

1016 mm (40)
711 mm (28)
762 mm (30)

893
844 and 894

762 mm (30)
914 mm (36)
965 mm (38)

1243 and 1293

762 mm (30)

These figures are approximate and vary with seed size and variety. Seeds are gathered directly behind the separator.

OUO6075,00018F6 1928JUN011/1

75-7

101801

PN=259

Crop Settings and Seed Loss Charts

Power Shutdown Procedure


NOTE: This procedure is the correct method for performing a power shutdown of the separator. The purpose of a power shutdown is to determine the machines performance in the threshing and separating areas by taking a "snap-shot" of the material on the straw walkers. This is valuable in determining where the losses behind the machine are generated and what adjustments can be made to correct the condition.
1. Operate the machine to fill with crop. 2. Pull the multi-function lever to neutral and then quickly complete step 3. 3. Momentarily shut off the key switch (A) to kill the engine while reaching over with left hand and disengage the header (B) and separator (C) engage switches on the armrest console. Quickly restart the engine to allow for turbo charger lubrication. 4. After 30-60 seconds at slow idle shut off the engine. 5. Inspect for excessive grain damage, kernels left on the cobs, and free grain loss before making any adjustments. 6. Once you have decided what adjustments need to be made, open the concave clearance and engage the separator (this will avoid undue stress to the cylinder drive area during clean out). 7. Adjust the machine to the desired settings and proceed harvesting. 8. Repeat this procedure and verify grain quality and losses behind the combine. 9. Once acceptable loss levels are attained, set the sensitivity on the VISIONTRAK Monitor and continue to harvest.
UN12MAY99

AKey Switch BHeader Engage Switch CSeparator Engage Switch

OUO6075,0001754 1930MAY011/1

75-8

PN=260

H57124
101801

H68048

UN16MAY01

Combine Cleanout
Cleaning Out the Combine
CAUTION: To prevent injury, never clean the combine with the engine running and the separator engaged. The following instructions are recommended when cleaning out the combine for certified seed crops or when transporting the combine inter-state. CAUTION: Block header safely so it will not move. Lower reel safety stops. Remove header from combine. Drive combine over end rows or bumps to jar and shake dirt loose. Stop engine, set parking brake and remove key.
UN07JUN01

Open or remove all doors and drain holes. CAUTION: Sound horn (A) to clear everyone from area. Stay clear of combine when discharging chaff. Start engine and let separator run until chaff stops coming out rear. Lower engine rpm to low idle and engage separator several times. The "jogging" of separator at low idle removes dirt from inside of cylinder. Move throttle to high rpm and run for a few minutes. Repeat cycle until chaff no longer comes out of the rear of the combine. CAUTION: Keep bystanders clear of combine when discharging chaff. Drive combine straight back 3 m (10 ft.) onto blocking so right-hand side is about 150 mm (6 in.) higher, or park on incline so dirt can run out. Stop engine and remove key.
AHorn
OP ST

Continued on next page

OUO6075,0001772 1931MAY011/19
101801

80-1

PN=261

H68490

Combine Cleanout
Set parking brake and block wheels.

OUO6075,0001772 1931MAY012/19

CAUTION: When working with compressed air in dusty conditions, you must wear goggles and dust mask for personal protection. Air hose must have a 2 m (6 ft.) wand (end).
UN11OCT88

Start at top of combine and work down.

OUO6075,0001772 1931MAY013/19

CAUTION: Stop engine, set park brake and remove key. Clean grain from under grain tank cross augers over to the sump.
UN03JUL01

Clean grain from edges of unloading auger sump to the bottom. Grain must be cleaned out from these doors as you are standing on the ground.
ACleanout Doors BCleanout Doors CCleanout Doors

OUO6075,0001772 1931MAY014/19

Using a four meter (foot) air nozzle (A) insert one meter (foot) of the nozzle into bottom hole of the right hand primary support bracket (B) and blow material out. Continue inserting the nozzle one meter (foot) at a time and blow out the remaining material.
AFour Foot Air Nozzle BRight Hand Primary Support Bracket
UN19MAY99

Continued on next page

OUO6075,0001772 1931MAY015/19
101801

80-2

PN=262

H57343

H69028

H39607

Combine Cleanout
Release clamp (A) and open lower clean grain elevator door (B).
AClamp BLower Clean Grain Elevator Door
UN18FEB99

OUO6075,0001772 1931MAY016/19

Loosen clamps (A) and swing grain tank window (B) up. Clean out area behind cab, around primary countershaft and over cylinder.
AClamps BGrain Tank Window

OUO6075,0001772 1931MAY017/19

Remove panel in rear of grain tank and clean out this side of engine area.

Continued on next page

OUO6075,0001772 1931MAY018/19

80-3

101801

PN=263

H51794

UN15JAN99

H60952

UN04OCT99

H54048

Combine Cleanout
Open shield (A), cover (B) and swing ladder up. Clean entire engine compartment area, especially under engine and over condenser. Wipe up oil and grease.
AShield BCover
UN26APR01

OUO6075,0001772 1931MAY019/19

Remove screen (A) and cleanout.


AScreen

OUO6075,0001772 1931MAY0110/19

Clean radiator, oil cooler, condenser, and rotary screen from inside out. Clean off top of fuel tank.

Continued on next page

OUO6075,0001772 1931MAY0111/19
101801

80-4

PN=264

H68049

UN16MAY01

H67126

UN02APR01

H68047

UN16MAY01

H67700

Combine Cleanout
Open lower tailings elevator door (A). Remove wing nuts (B) and remove door at upper end of elevator. Clean down all sides of elevator and clean out cross auger trough.
AElevator Door BWing Nuts
UN15JAN99

OUO6075,0001772 1931MAY0112/19

Remove cap screw (A) and turn handle to unlock door (B). Repeat on opposite side. Clean out chaff between cylinder and side sheets. Clean remaining chaff and seed from concave and cylinder. Also clean inside of cylinder. Clean upper tailings auger housing on the inside and the area around it.
ACap Screw BDoor
UN31MAY01

Continued on next page

OUO6075,0001772 1931MAY0113/19

80-5

101801

PN=265

H68052

H51786

UN15JAN99

H51785

Combine Cleanout

CAUTION: The feed plate seal, through normal operation, develops a sharp edge. Avoid bodily injury from contact with sharp edge when servicing this area.
UN16MAY01

Clean feeder house through top doors (A) and (B). Lift conveyor chain and let snap back several times while cleaning.
ATop Doors BTop Doors

OUO6075,0001772 1931MAY0114/19

CAUTION: Stop engine, set parking brake and remove key. Lower safety stop before working under feeder house. Lower stone trap and feed plate. Clean areas out.
UN03JUL01

Continued on next page

OUO6075,0001772 1931MAY0115/19

80-6

101801

PN=266

H69030

H68053

Combine Cleanout
Remove conveyor auger door. Use scraper to loosen material, then clean out through the sides of the combine. Then clean off top of axle and transmission.

OUO6075,0001772 1931MAY0116/19

CAUTION: When cleaning straw walker and beater area, cardboard, canvas, or carpet must be placed on top of walkers. Remove straw walker curtains, then clean walkers and power separator through inspection door. Clean deflectors at front of walkers and work your way to the rear. Clean between walkers and between walkers and side sheets and around crank bearings. Clean beater and its wings. Also clean between beater and shield on side sheet and inside of beater and wings.

Continued on next page

OUO6075,0001772 1931MAY0117/19

80-7

101801

PN=267

H68719

UN13JUN01

H67701

UN26APR01

H39612

UN11OCT88

Combine Cleanout
Remove sieve, chaffer and precleaner sections. Clean out chaff from areas where sides meet. Open sieve, chaffer and precleaner as far as possible and clean. Clean out tailings and clean grain auger troughs. Clean rear axle area.
UN04OCT99

OUO6075,0001772 1931MAY0118/19

Remove lower shield (A) and clean out cleaning fan area. Clean header and platform equipment. See specific header or platform operators manual.
ALower Shield

OUO6075,0001772 1931MAY0119/19

80-8

101801

PN=268

H69335

UN18JUL01

H61008

Feeder House
Hydraulic Cylinder Safety Stop
CAUTION: Engine must be off, parking brake set and key removed.
UN21SEP89

Cracking of hydraulic line fittings to lower feeder house results in an instantaneous dropping of feeder house and header. Lower safety stop (A) onto hydraulic cylinder rod.
ASafety Stop

OUO6075,00018F7 1928JUN011/1

Feeder House Side Shields


CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. The right-hand and left-hand side feeder house has a front and rear shield. Loosen steel strap (A) and swing the front shield open for service. Remove cap screw (B) to remove rear shield.
ASteel Strap BCap Screw
UN18JUL01

OUO6075,0001965 1918JUL011/1

85-1

101801

PN=269

H69337

H69336

UN18JUL01

TS696

Feeder House

Feeder House Doors


CAUTION: Engine must be off, key removed, and parking brake set.
UN16MAY01

Loosen nuts (A), slide latches in and pull door (B) forward to remove. To access inside of feeder house, remove bolts and lift doors (C).
ANuts BDoor CDoor

OUO6075,0001800 1915JUN011/1

Cylinder Top Access Door


CAUTION: Engine must be off, key removed, and parking brake set.
UN31MAY01

Remove cap screw (A) and turn handle. Repeat on opposite side. Pull on handles to unlock and remove door (B).
ACap Screw BDoor

OUO6075,0001787 1904JUN011/1

85-2

101801

PN=270

H68052

H68054

Feeder House

Bottom Feeder House Door and Feedplate Seal Support


CAUTION: Raise feeder house, lower safety stop, shut off engine, remove key, and set parking brake. Move lever (A) down and to rear to open door. IMPORTANT: Lever will be bent if left open when feeder house is lowered. Pull lever forward and up to close.
ALever

OUO6035,000006C 1909NOV001/2

If feeder house door is not sealing tight at (A) grain leakage could occur. Loosen cap screws (B) on both sides. Turn eccentric (C). Tighten cap screw securing eccentric. Tighten remaining cap screws.
ASeal BCap Screws CEccentric
UN18JUL01

OUO6035,000006C 1909NOV002/2

85-3

101801

PN=271

H69339

H69338

UN18JUL01

Feeder House

Stone Trap
CAUTION: Raise feeder house, lower safety stop, shut off engine, remove key, and set parking brake. A stone trap protects the cylinder and concave from damage. Raise feeder house, lower safety stop, shut off engine and remove key. To dump stone trap, move lever (A) up. Close by pushing lever down.
ALever
UN03JUL01

OUO6075,0001926 1929JUN011/1

Adjusting Fore/Aft Tilt Frame


CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. Loosen tilt frame nuts (A) and center pivot bolt (B) on both sides of the feeder house. Loosen both turnbuckle stop nuts (C).
UN19FEB01

NOTE: Distance is measured from center of eyebolt to center of eyebolt.


Adjust turnbuckle (D) to specification.
Specification TurnbuckleDistance ................................................................... 315 mm (12 in.)

Tighten frame nuts and pivot bolts to specification.


Specification Frame Nuts and Pivot Bolts Torque .......................................................................................... 215 Nm (159 lb-ft) ATilt Frame Nuts BPivot Bolts CTurnbuckle Stop Nuts DTurnbuckle

OUO6075,0001804 1915JUN011/1

85-4

101801

PN=272

H66456

UN19FEB01

H66452

H69031

Feeder House

Adjusting Feeder Conveyor Chain


CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. IMPORTANT: Check chain tension (both sides), every 100 hours. Adjust chain when outside strand touches front of the runner channel (D). To adjust chain: Open feeder house shields. Loosen nut (A) on both sides of feeder house. Adjust eyebolt (B) with adjustment nuts (C) on both sides of feeder house, until left-hand and right-hand side of outer chain contacts the runner past air flow opening, to keep air flow open. Tighten jam nut and eyebolt adjustment nuts.
UN24FEB00 UN03JUL01

The chain should be no tighter than runner contact at center of the door opening. Do not over-tighten chain to make center strands as tight as outer strands. Center strands normally sag more because of weight of slats and upward force from crop material. Bent eyebolts indicate excessive chain tension or slug feeding. Out-of-round sprockets or drum and bent shafts can cause chain tension to be uneven, too tight, or too loose. Shaft and bearing failure, and premature chain wear are often caused by excessive chain tension. When the adjusting eyebolt can go no further and the chain needs more tensioning, remove an offset link (see REMOVING CONVEYOR CHAIN LINKS in this section). Close shields.
AJam Nut BEyebolt CNuts DFront Runner Channel

OUO6075,0001803 1915JUN011/1

85-5

101801

PN=273

H62798

H68977

Feeder House

Removing Conveyor Chain Links


CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. First shorten chain as required. Remove offset link (A) for initial shortening. Secondly as required: Remove inside link (B) and replace it with an offset link. The offset link now becomes the coupler link. Repeat this procedure on all strands of chain. When adjustment is all used up, the chain is worn out and should be replaced.
UN13JUN00

AOffset Link BInside Link CLinks (3 Used)

OUO6075,0001927 1929JUN011/1

Checking Feeder House Conveyor Float


CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. Conveyor slats must clear the floor by 3 mm (1/8 in.) for grain or 25 mm (1 in.) for corn as measured between a conveyor slat and feeder house bottom, directly under feeder drum at (A).
Specification Conveyor SlatGrain Clearance .......................................................................................... 3 mm (1/8 in.) Conveyor SlatCornClearance................................................... 25 mm (1 in.)
UN12SEP98

ADistance of 3 mm (1/8 In.) Between Conveyor Slat and Feeder House Bottom

OUO6075,0001806 1915JUN011/1

85-6

101801

PN=274

ZX015585

H64189

Feeder House

Drum Height Adjustment


CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. 1. Open right-hand feeder house side shields. 2. Pull and hold pin (A) while rotating handle (B) counter clockwise to small grain position. 3. For grain slat clearance, loosen nut (C) and (D), rotate cam (E) to get 3 mm (1/8 in.) slat clearance between slat and feeder house bottom. Repeat this procedure on left-hand side. Tighten nut (D) to specification.
Specification Drum Adjusting NutTorque ....................................................... 115 Nm (85 lb-ft)
UN22FEB01

Corn Only Position

4. Tighten nut (C) and place handle in desired crop position.


APin BDrum Height Handle CNut DNut ECam

Small Grain Position

OUO6075,000154A 1922FEB011/1

Changing Feeder Conveyor Speed


CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. The feeder conveyor chain can be set to two different speeds by selecting the drive sprocket (A) on the right hand side of the lower shaft. Use small sprocket for slow speed and large sprocket for high speed.
ADrive Sprocket
UN09JUN00

Continued on next page

OUO6075,0001472 1919FEB011/2
101801

85-7

PN=275

H64191

H66532

UN21FEB01

H66531

Feeder House
NOTE: If you have low feed rate conditions, you can decrease the conveyor speed and improve part life by moving the conveyor chain to the small sprocket. If you have material handling or crop damage problems increase the speed of the conveyor chain by moving it to the large sprocket.
To move the chain to the smaller sprocket: Open front shields. Loosen nut (A) and push sprocket rearward. Loosen nut (B) and move sprocket to upper position. Push in on coupler and move small sprocket (C) outward until it engages detent. Engage chain onto sprocket. Move sprocket to lower position (D) and tighten nut (B). Use pry bar in holes of inside plate to move sprocket forward and tighten nut (A). Close front shield.
ANut BNut CSmall Sprocket DLower Position
UN28FEB01

OUO6075,0001472 1919FEB012/2

Adjusting Feeder Conveyor Drive Chain


CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. Open front shield. Loosen nut (A) and push sprocket rearward. Use pry bar in holes of inside plate to move sprocket forward and tighten nut (A). Tighten nut and close shield.
ANut
UN19FEB01

OUO6075,0001474 1919FEB011/1

85-8

101801

PN=276

H66467

H66465

H66464

UN19FEB01

Feeder House

Slip Clutch
CAUTION: Shut off engine, set parking brake and remove key.
UN18JUN01

Loosen cap screw (A). Adjust clamping nut (B) by turning clock-wise or counter-clockwise. Adjust clutch (C) to adjusting length (X) specification.

B
UN19JUL01

ACap Screw BClamping Nut CClutch XAdjusted Length Item Measurement Specification

Top Shaft Slip Clutch

Gap

12 mm (0.47 in.)

Tighten cap screw.

OUO6075,0001966 1918JUL011/1

85-9

101801

PN=277

ZX25119

ZX25161

Feeder House

Feeder House Top Shaft Stripper Adjustment


CAUTION: Shut off engine, set parking brake and remove key. If the top feeder house shaft should wrap, check to see that the strippers are adjusted as follows: Remove top feeder house door. Loosen bolts (A) and set stripper (B) to 3 mm (1/8 in.) (C) from top shaft (D).
Specification Stripper LocationDistance .............................................................. 3 mm (1/8 in.) ABolts BStripper CDimension 3 mm (1/8 in.) DTop Shaft
UN18AUG99

Tighten bolts (A) and re-install top feeder house door.

OUO6075,0000323 1905JAN011/1

Feeder House Top Shaft Sprockets


After 1000 hours, depending on the crops being harvested, check the upper shaft sprockets for wear. If these sprockets are worn past 12 mm (1/2 in.) (A), sprockets can be reversed for additional wear.
ADimension 12 mm (1/2 in.)

H59570

OUO6075,0001756 1930MAY011/1

85-10

101801

PN=278

H39620

UN11OCT88

Feeder House

Adjusting Fixed Speed Feeder House Belt

C
A

ANuts

BBelt

CWasher

DGauge

CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key.

Tighten nuts (A) until washer (C) aligns with end of gauge (D). This will correctly tension belt (B).

OUO6075,00018F9 1928JUN011/1

HEADERTRAK Tilt Indicator


For a quick visual indication of whether the header is level with the combine chassis, the HEADERTRAK is equipped with a manual tilt indicator. When the notch (A) is in the center of the rubber seal, the header is approximately level with the combine body. The indicator may also be useful as a reference during operation.
ANotch
UN24JAN00

OUO6075,00013D2 1902FEB011/1

85-11

101801

PN=279

H62284A

H68115

UN04JUN01

Feeder House

Removing Header from Feeder House


CAUTION: Do not leave drive shafts on combine. Personal injury or machine damage may occur if feeder house is accidentally engaged. IMPORTANT: Drive shafts with U-joints are used on the left-hand and right-hand sides of all approved headers.

NOTE: For complete attaching and detaching procedures refer to the header Operators Manual.
Disconnect telescoping drive shafts from feeder house at the quick disconnect coupler (A) on left and right sides. Place telescoping drive shafts in storage position (B).
AQuick Disconnect Coupler BStorage Position

OUO6075,0001477 1919FEB011/1

85-12

101801

PN=280

H66471

UN19FEB01

H66470

UN19FEB01

Separator
Left-Hand Drives

B A D E

AHeader and Reel Pump Belt BUnloading Augers (Chain)

CChopper Belt DCleaning Fan Belt

EFeeder House Drive Belt (Level Land) Feeder House Drive Belt (HILLMASTER II)

FPower Separator Belt

Continued on next page

OUO6075,000197B 1925JUL011/2

90-1

101801

PN=281

H69425

UN26JUL01

Separator

AUpper Tailings Auger (Chain)

BLower Tailings Auger (Chain)

CBeater; Regular (100%), Optional (75%)

DUnloading System

OUO6075,000197B 1925JUL012/2

90-2

101801

PN=282

H69426

UN26JUL01

Separator

Right-Hand Drives

A
D

AAccessory Drive Belt

BSecondary Countershaft Belt

CFeeder Conveyor (Chain)

DShoe, Walker and Conveyor Augers, Belt

Continued on next page

OUO6075,000197C 1925JUL011/2

90-3

101801

PN=283

H69427

UN26JUL01

Separator

ACooling Fan Belt BRotary Screen Belt CRotary Screen Drive Belt

DClean Grain Elevator Belt ECylinder Intermediate Drive Belt, 240-980 rpm, 470-960 rpm

FCylinder Drive Belt, 240-980 rpm and 470-960 rpm

GLower Tailings Auger and Elevator, Belt

OUO6075,000197C 1925JUL012/2

Dual-Range POSI-TORQ Cylinder Drives


The standard Dual-Range Cylinder Drive has a high range (direct drive) of 480-980 rpm and a low range (reduction drive) of 240-480 rpm.
240
B

480 480

980
UN26JUL01

OUO6075,000197D 1925JUL011/1

90-4

101801

PN=284

H69429

H69428

UN25JUL01

Separator

Single-Range Cylinder Drive


A single range drive of 470-960 rpm is furnished on grain combines.

OUO6075,0001974 1924JUL011/1

Dual Range Cylinder Drive Shear Bolts


Shear bolt (A) is located in the cylinder drive sheave. Extra bolts are located at (B) for storage. IMPORTANT: Use only 1/4 x 3 in. Grade (D) bolts (John Deere part number 19H2151).
AShear Bolt BExtra Bolts

OUO6075,0001967 1918JUL011/1

90-5

101801

PN=285

H53041

UN15FEB99

H69340

UN18JUL01

H42621

UN25SEP90

Separator

High-Range Direct Drive (480-980 RPM)


CAUTION: Shut off engine, remove key, and set parking brake.
UN18JUL01

Align notched area of wheel (A) to one of three holes in gear case sheave (B). Notch area may have to be rotated 360 up to three times to align holes in cylinder drive sheave and speed pickup casting (C). Insert pin (D) in hole and into speed pickup casting. Insert safety pin (E) through pin and on both sides of lip surrounding hole. Lock safety pin.
AWheel BGear Case Sheave CSpeed Pickup Casting DPin ESafety Pin

OUO6075,0001968 1918JUL011/1

Low Range (Reduced-Drive) (240-480 RPM)


CAUTION: Shut off engine, remove key and set parking brake.
UN18JUL01

Pull down on arm (A) and align lug (B) on torque wheel with arm (A). Insert pin (C) through hole in arm and lug as far as it will go. Insert safety pin (D) through pin and on both sides of tabs on arm. Lock safety pin. Cylinder will now operate in reduced drive at 240-480 rpm (or about 150-250 rpm with a low speed cylinder drive conversion).

AArm BLug CPin DSafety Pin

OUO6075,0001969 1918JUL011/1

90-6

101801

PN=286

H69342

H69341

Separator

Unplugging Cylinder with Breaker Bar


CAUTION: Before applying breaker bar, disengage separator, shut off engine, remove key and set parking brake. After clearing cylinder, remove breaker bar before restarting engine and engaging separator. If cylinder becomes choked, open concave and run separator to clean cylinder. CAUTION: Raise feeder house, lower safety stop, shut off engine, remove key, and set parking brake. If cylinder remains choked, shut off engine. Leave concave fully opened to remove all straw and other material from front of concave through cylinder (top) front door or bottom cleanout door.

OUO6035,000006E 1909NOV001/2

NOTE: The breaker bar is for a dual range cylinder; it is not provided with the combine. The breaker bar can be made out of steel. Dimensions for making the bar are provided. If combine is equipped with single range cylinder drive, use a crowbar or breaker bar to unplug the cylinder.
Remove the shield covering the dual range cylinder. Insert breaker bar (B) and rock the cylinder back and forth until it is clear. Slide shield back into position and secure with cap screw. Adjust concave to original position after cylinder has been cleared.
Dual Range Cylinder Breaker Bar
BBreaker Bar
UN03AUG92

OUO6035,000006E 1909NOV002/2

90-7

101801

PN=287

H44940

Separator

Power Unplugging of Cylinder


Shut off separator and header. Open the concave to the full open position. Turn off engine, remove key and set parking brake. Remove safety pin, then remove pin from cylinder drive. Open stone trap and clean. Sound horn, start engine and set engine speed at low idle. Engage separator to clean out material. Set cylinder speed to mid range. Shut off separator. Resume operation. Turn off engine, remove key and set parking brake. Using cylinder drive locking pin already removed, place cylinder drive in low range and lock with pin and safety pin. (If originally operating in high-range) Remove safety pin and pin from cylinder drive and shift back to high-range (direct drive). Replace pin and safety pin. When cylinder is unplugged, set concave and cylinder speed back to original setting. IMPORTANT: To prevent damage to engine PTO gearcase and wet clutch, do not engage separator clutch with plugged cylinder more than three times in a period of three minutes with engine at high idle. Turn off engine, remove key, and set parking brake. Sound horn, start engine and set engine speed at low idle.

HX,AG,SF6972 1917MAY991/1

90-8

101801

PN=288

Separator

Setting Cylinder Access Door to Cylinder


If the front door is not correctly adjusted, crop can feed back down on the top of the feeder house. Loosen bolts (A) holding seal (B) to cylinder front door. Position seal to 12 mm (1/2 in.) (C) between seal and rasp bar (D). Tighten bolts.
ABolts BSeal C12 mm (1/2 in.) DTip of Rasp Bar

HX,AG,SF6973 1920MAR901/1

Cylinder Vibration
Should cylinder vibration occur, remove the perforated filler plates and clean the inside of the cylinder.
HX,AG,SF6974 1925OCT951/1

90-9

101801

PN=289

H39131

UN11OCT88

Separator

Rear Concave Inserts (Corn Combines)


Converts a short wire concave for harvesting corn. The inserts (A) (which can also be used with the spike tooth concave) prevent corn cobs from passing through the open area at the rear of the short wire and spike tooth concave to ensure complete threshing. Guidelines for when and when not to use inserts: Corn - Concave inserts should always be used when harvesting high moisture corn (above 20%). Because tighter concave settings are used to help get the kernel off the cob, the inserts will hold any broken cob pieces with unthreshed kernels in the concave area for more complete threshing. Without the inserts, these cob pieces with unthreshed kernels can fall through the concave on to the cleaning area (chaffer) and can be found as unthreshed field loss. In high moisture corn, the inserts will also prevent the large open rear area of the concave from plugging with green, damp husk and cob pieces. The inserts can be removed in lower moisture (below 20%) where the husks are dryer and corn shells easier (lower threshing speeds). In dry corn at faster ground speeds (than typically used in wet corn) removal of the inserts will allow additional separation needed at the higher harvesting speeds. Soybeans - The use of concave inserts is primarily for corn. Inserts (in or out) generally do not affect performance in soybeans. Therefore, if the inserts have been installed for high moisture corn and there is a need to harvest soybeans the same day, do not remove the inserts. If the inserts have been removed and there is a need to harvest soybeans the same day, do not install the inserts.

AInsert

NOTE: If hard-to-thresh soybeans or high cleaning shoe load conditions exist, installing the inserts may be beneficial.

HX,AG,SF6979 1923FEB961/1

90-10

101801

PN=290

H43648

UN01JUL91

Separator

Front Concave Closure Plates (Attachment)


The covers (A) are installed on the bottom side of the concave and covers the front open portion of the corn and short wire concaves. These covers assists in threshing hard-to-thresh wheat, barley, clover, flax and some grass seeds. The covers are not recommended for the spike tooth concave.
ACovers

OUO6035,000006F 1909NOV001/1

Rear Concave Closure Plates (Attachment)


The covers (A) are installed on the bottom side of the concave and covers the rear open portion of the short wire and spike tooth concave. The covers help avoid overloading the cleaning shoe when harvesting safflower or similar brittle stemmed crops.
ACovers

OUO6035,0000070 1909NOV001/1

90-11

101801

PN=291

H59655

UN23AUG99

H59654

UN23AUG99

Separator

Second Concave Curtain (Attachment)


Helps reduce walker loss. The rubber curtain (A) attaches to the rear of the second concave and in some conditions can help prevent separated grain from falling through the rear of the concave or from getting onto the front section of the straw walkers.
ARubber Curtain
UN27AUG94

HX,AG,SF6982 1912SEP941/1

Power Separator
The power separator has retracting tines, mounted on a rotor, which are used to pull and release the straw in a combing action. The combing action is designed to thin the crop mat and allow grains embedded in the material to be separated by the walkers.
APower Separator

OUO6075,00018FB 1928JUN011/1

Straw Walkers/Power Separator Access Door


Lift door (A) to clean straw walker and power separator.
ADoor
UN18JUN01

OUO6075,00018FC 1928JUN011/1

90-12

101801

PN=292

H68720

H68709

UN13JUN01

H46218

Separator

75 Percent Beater Speed (Optional)


The beater normally runs at 100 percent of the cylinder speed, but parts are available from your John Deere dealer to allow the beater to run slower (75 percent) in some crops. This slower speed beater drive can be used in crops when kernel damage must be kept to a minimum, such as food corn and edible beans.

HX,AG,SF6984 1901MAR991/1

Separator Curtains
Curtains control the flow of material from the beater over the straw walkers. A curtain is removed from inside the combine. To remove curtain, remove spring locking pins (A). Push one end of pipe (B) inside of side sheet. Remove curtain by sliding pipe through curtain.
ASpring Locking Pins BPipe

OUO6075,0000120 1901DEC001/1

Straw Walker Extension Pans


These pans, at the rear of straw walkers, can be extended to increase separation area.
UN11OCT88

These pans cannot be used in the extended position when using the straw chopper corn kit. CAUTION: Engine must be off, key removed, and parking brake set. Remove two bolts and move all pans in or out. These pans are not used on the outside straw walkers.

HX,AG,SF6986 1901MAR991/1

90-13

101801

PN=293

H39762

H43932

UN03OCT91

Separator

Straw Walker Sunflower Flaps


These rubber flaps are attached to the ends of the walkers to prevent "hair pinning" of sunflower stalks.
UN11OCT88

HX,AG,SF6987 1901MAR991/1

Slow Speed Cleaning Fan Drive (Attachment)


A slow speed drive is available from your John Deere dealer. This drive has a range of 490 to 980 rpm and is recommended for use in light weight crops such as grass seeds only.

HX,AG,SF6990 1901MAR991/1

Chaffer Fingers Storage


Store chaffer fingers (A) on the tailings elevator.
AChaffer Fingers
UN04JUN01

OUO6075,0001773 1931MAY011/1

90-14

101801

PN=294

H68374

H51901

UN28JAN99

H39763

Separator

Using Chaffer Fingers


These fingers are installed during normal conditions, but are removed when operating on hillsides. When operating on a slope, this prevents crop that is moved to the downhill side, from falling over the end of the shoe. This crop is then put through tailings return. IMPORTANT: The extra tailings puts a load on the tailings auger and, if tailings auger slip clutch has been over greased, it will slip. Remove and clean. Grease must be only on shaft, not on jaws.

OUO6035,0000071 1909NOV001/1

Precleaner Tool Storage


Be certain precleaner adjustment tool (A) is locked in place.
APrecleaner Adjustment Tool

OUO6075,00016AE 1914MAY011/1

Adjusting Precleaner
To adjust precleaner, use the tool (A) provided. Place the end of the tool into the adjustment linkage on the precleaner. One turn of the adjusting handle equals 3 mm (1/8 in.) opening of the precleaner louvers.
APrecleaner Tool
UN04OCT99

AG,OUO1035,340 1901MAR991/1

90-15

101801

PN=295

H61206

H67978

UN14MAY01

H61205

UN11OCT99

Separator

Adjusting Chaffer, Chaffer Extension and Sieve


NOTE: The chaffer extension adjusting process is similar to the chaffer adjusting process
Chaffer can be adjusted with lever (A) and notched dial scale. One notch on the dial scale is equal to 1 mm (1/32 in.). Remove the chaffer fingers to access the sieve adjusting lever (B).
ALever BSieve Adjusting Lever
UN04OCT99

AG,OUO1035,339 1901MAR991/1

Chaffer Finger Bar Cover (Attachment)


A cover (A) over these fingers may be used when harvesting sorghum. It keeps the sorghum stalks from dropping through the finger openings and sticking into the chaffer.
ACover

OUO6035,0000078 1909NOV001/1

90-16

101801

PN=296

H59666

UN23AUG99

H61208

UN04OCT99

H61207

Separator

Clean Grain Elevator Top Access Cover for Drives


Remove covers (A and B) to access belt (C).
ACover BCover CBelt

OUO6075,000180B 1915JUN011/1

Perforated Screens (Attachment)


Perforated screens are available for the lower door and the clean grain auger trough. They help sift out dirt, weed seed and fines. These parts also include screens for the tailings elevator.
UN24OCT96

HX,AG,SF7006 1914JAN971/1

90-17

101801

PN=297

H48118

H53061

UN18FEB99

H68500

UN04JUN01

Separator

Tailings Elevator Paddles


Check elevator chain occasionally for worn or missing paddles. Also check the upper beater paddle. In muddy conditions, one steel paddle may be installed in the elevator chain to act as a wiper. See your John Deere dealer for parts.

OUO6035,0000079 1909NOV001/1

Separator Countershaft Strips


These strips (A) move stiff, brittle stalks from the rear of the precleaner. They are standard equipment on all rice combines with spike-tooth and rasp bar cylinders. They are also helpful when harvesting safflower with the grain concave. These strips can be easily removed if long, viney material wraps the shaft.
AStrips
UN23AUG99

OUO6035,000007A 1909NOV001/1

Tailings Elevator Slip Clutch


This slip clutch is correctly set at the factory. If it is ever repaired, tighten nut (A) against the shoulder of the shaft. This will correctly compress spring (B).
ANut BSpring
UN23AUG99

OUO6035,000007B 1909NOV001/1

90-18

101801

PN=298

H59672

H59669

H60949

UN04OCT99

Chopper and Spreader


Chopper (General Information)
CAUTION: Do not let anyone stand behind the chopper while it is running. Combine engine must be off, key removed, and parking brake set before adjusting chopper. Normal use wears the bottom of the chopper vanes to a sharp edge. The optional fine cut choppers have twice as many blades as the standard chopper. The fine cut chopper has straight blades with double edged sharpened blades, good where yields and tough straw crops are harvested with narrow 7.6 m (25 ft) or less headers.

OUO6075,00018FD 1928JUN011/2

IMPORTANT: If harvesting corn, chopper speed must be set at low speed (1200 rpm) to avoid damage to chopper housing, tailboard, and vanes. There are two tailboard configurations available for use with choppers: Regular Wide Spread. The widespread chopper tailboard vanes are twice as deep as the standard chopper vanes and capable of distributing straw residue over 9.1 m (30 ft.)

Regular Tailboard

OUO6075,00018FD 1928JUN012/2

95-1

101801

PN=299

H69343

UN18JUL01

H68710

UN13JUN01

Chopper and Spreader

Adjusting Chopper Vanes (Manual)


CAUTION: Shut off engine, remove key, and set parking brake.
UN15DEC98

Adjust vanes (A) so material is spread over a wide area but does not cover uncut crop. Loosen bolts (B), adjust vanes and tighten bolts.
AVanes BBolts

OUO6075,000167E 1927APR011/1

Adjusting Chopper Vanes (Electrical)


NOTE: If vanes do not produce adequate spread width or even distribution, adjustments can be made to the linkage components.
If the wind is blowing from the side, set chopper vanes against the wind to prevent the standing crop from becoming covered with chopped material. This setting can be retained if the combine drives around the field in a circle and not up and down its length. Electrical Adjustment
AElectric Motor
UN16MAY01

Straw deflector vanes are adjusted centrally by means of electric motor (A). The adjustment is made from the operators cab.

OUO6075,000180D 1915JUN011/1

95-2

101801

PN=300

H68065

H51545

Chopper and Spreader

Adjusting Knives
CAUTION: Engine must be off, key removed and parking brake set.
UN18JUL01

Knives can be adjusted to any position. Position of knives determines the cut length of straw. IMPORTANT: Knives must be in position (C) (not cutting) position for corn. For longer straw, loosen bolt (A and B) (both sides) and rotate knife bank up to position (C). Tighten bolts. For shorter straw, loosen bolt (A and B) (both sides) and rotate knife bank down to position (D). Tighten bolts.

ABolts BBolts CLonger Crop Material DShorter Crop Material

OUO6075,000196A 1918JUL011/1

Chaff Spreader (Optional)


The chaff spreader is recommended for crops that generate large volumes of residue from the separator cleaning system.
UN18MAY01

OUO6075,00016BE 1916MAY011/1

Chop to Drop
CAUTION: Engine must be off, key removed and parking brake set.
UN13JUN01

Chop to drop bypasses the chopper and spreader. When chop to drop is open material is allowed to fall into windrows. Use handle (A) to open or close the chop to drop.
AHandle

OUO6075,00018FE 1928JUN011/1

95-3

101801

PN=301

H68713

H68068

H69350

Chopper and Spreader

Raising and Lowering Chopper Vane Board


NOTE: Chopper vane board can be adjusted to three different positions by pulling out knob (A) and lifting or lowering chopper vane board.
UN18JUL01

Pull out and rotate knob (A) (both sides). Lift chopper vane board upward until latched. Lift latch (B) and slowly lower chopper vane board until desired position and rotate knob to secure chopper vane board.
AKnob BLatch

OUO6075,000196B 1918JUL011/1

95-4

101801

PN=302

H69352

UN18JUL01

H69351

Chopper and Spreader

Adjusting Spreader Disk Vanes


NOTE: Check daily for trash build-up beneath the twin disks and clean out as required.
Should plugging occur between the disks (I) during operation, the vanes may have to be repositioned. For corn or soybeans, the vanes should be positioned with 45 angle (J) installed to the outside of the disks. For small grain, the vanes should be positioned with the square end (K) of the vanes installed to the outside. When repositioning the vanes, the vanes (A), (B), (C), and (D) on the left-hand side disk must be reinstalled on the right-hand side disk. The vanes (E), (F), (G) and (H) on the right-hand side disk must be reinstalled on the left-hand side disk.
ADLeft Hand Side Vanes EHRight Hand Side Vanes IDisks J45 Angle KSquare End

Vanes Positioned for Corn or Soybeans

Vanes Positioned for Small Grain

OUO6075,000177E 1931MAY011/1

95-5

101801

PN=303

H44999

UN15FEB93

H44998

UN15FEB93

Chopper and Spreader

Removing the Chaff Spreader


CAUTION: Chaff spreader is heavy and awkward to handle. Use two service technicians or a safe lifting device to remove spreader. To remove the chaff spreader, disconnect the hydraulic hoses (A) from the chaff spreader. Remove cap screws (B) securing chaff spreader to support. Remove spreader.
AHydraulic Hoses BCap Screws
UN18MAY01

OUO6075,00016BF 1916MAY011/2

Connect hydraulic hoses (A) together. Secure hoses to support or rear axle where hoses will not get pinched when operating combine.
AHydraulic Hoses
UN16NOV99

OUO6075,00016BF 1916MAY012/2

95-6

101801

PN=304

H61846

H68069

Grain Tank and Unloading System


Grain Tank/Engine Ladder
CAUTION: Shut off engine, remove key and set parking brake.
UN18MAY01

Use ladder (A) to get into grain tank. Remove wing nut (B) and clamp (C) to swing ladder up for engine service. Always position clamp behind the ladder so the ladder is tilted. IMPORTANT: Do not step on top of fan cover (D) without wing nuts (E) installed, the fan cover will bend without the fan cover door for support.
ALadder BWing Nut CClamp DFan Cover EWing Nuts

OUO6075,00016C0 1916MAY011/1

Grain Tank Drain Holes


Grain tank drain hole doors (A) are located on the right-hand end of both cross augers and must be opened during storage or for cleaning grain tank. To open, loosen cap screws and slide doors away from drain holes.
ADrain Hole Doors
UN23FEB99

HX,AG,SF7023 1912SEP941/1

100-1

101801

PN=305

H52943

H68070

Grain Tank and Unloading System

Operating Grain Tank Covers


CAUTION: Grain tank covers must be closed before transporting combine on roads. IMPORTANT: Open grain tank covers before engaging separator. Actuator will not raise covers if tank is one third or more full. If grain tank is full, unload before raising covers. When covers are opened, the clean grain loading auger swings up with them. Auger swings down when covers are closed. Grain tank covers are electrically operated by an electric motor activated by switches located into operators cab and within the grain tank.
UN18MAY01

OUO6075,00016C1 1916MAY011/3

Operate Grain Tank Covers Cab To open the grain tank covers push and hold the open-symbol (I). To close the grain tank covers push and hold the close-symbol (II).
A
UN07JUN01

AGrain Tank Cover Switch IOpen-Symbol IIClose-Symbol

Continued on next page

OUO6075,00016C1 1916MAY012/3

100-2

101801

PN=306

H68425

H68071

Grain Tank and Unloading System


Operate Grain Tank Covers Grain Tank CAUTION: Shut off engine, remove key, and set parking brake before entering grain tank.
UN14MAY01

Switch (A) allows opening and closing the grain tank covers from within the grain tank. The grain tank cover switch is located on the right-hand side by the grain tank loading auger.
AGrain Tank Cover Switch

OUO6075,00016C1 1916MAY013/3

Adjusting Grain Tank 3/4 Indicator


The 3/4 tank sensor (A) is located on the front side next to the grain tank loading auger. It turns on a blue light on the warning display panel and a buzzer until the sensor is de-activated. The blue light turns on immediately but there is a two seconds delay between the tripping of the sensor (A) and the buzzer sounding. Adjust sensor by moving it up or down in slot. This adjusts the switch trip point.
A3/4 Tank Sensor
UN18MAY01

CAUTION: Shut off engine, set parking brake and remove key.

NOTE: Header drive must be on for the buzzer to sound.

OUO6075,00016C2 1916MAY011/1

100-3

101801

PN=307

H68073

H67985

Grain Tank and Unloading System

Adjusting Grain Tank Full Indicator


IMPORTANT: When the sensor is reversed, the sensor will then be higher than the grain tank extension. The full tank sensor (A) is located on the front grain tank cover. It turns on a blue light on the warning display panel and a buzzer until the sensor is de-activated. The blue light turns on immediately but there is a two seconds delay between the tripping of the sensor (A) and the buzzer sounding.
AFull Tank Sensor
UN18MAY01

CAUTION: Shut off engine, set parking brake and remove key.

NOTE: Header drive must be on for the buzzer to sound.


Adjust sensor (A) by moving it up or down in slot. This adjusts the switch trip point.

OUO6075,0001780 1931MAY011/1

Grain Tank Unloading Auger Covers (Optional) (Standard on Rice Combines)


CAUTION: Shut off engine, remove key and set parking brake. IMPORTANT: If these covers are open too far in rice or edible beans, the auger drive shear bolt may break repeatedly, or damage could occur to the augers or grain tank. Adjust these covers down to slow unloading rate. Also adjust them down in rice or edible beans. Loosen bolts (A) to adjust each cover (B).
UN11OCT88

ABolts BCover

OUO6075,000154F 1923FEB011/1

100-4

101801

PN=308

H39291

H68074

Grain Tank and Unloading System

Cross Auger Drive Shear Bolt


CAUTION: Set parking brake, shut off engine and remove key.
UN05OCT99

Shear bolt (A) protects the unloading auger system. Three extra bolts (B) are provided to the left of the drive. Use only a M8 x 60 class 8.8 cap screw as a shear bolt (John Deere part 19M7185). Coat machined face and pilot shoulder of hub with grease whenever shear bolt is replaced. IMPORTANT: Do not install a tire inner tube or a sack to end of unloading auger. Any restriction at end of auger can cause damage to the unloading auger system and could cause shear bolt failure.
AShear Bolt BExtra Bolts

OUO1035,00002A1 1920SEP001/1

Grain Tank Loading Auger Deflector


CAUTION: Shut off engine, set parking brake and remove key.
UN18MAY01

Grain tank loading auger deflector (A) pivots as grain tank covers rise. Grain tank loading auger out or up position: Windy conditions when harvesting crops like grass seed or rape. CornGrain tank will fill to the left and to the rear. Grain tank loading auger in or down position: GrainGrain tank will fill to the right and to the front.
AGrain Tank Loading Auger Deflector

OUO6075,0001815 1915JUN011/1

100-5

101801

PN=309

H68075

H61367

UN05OCT99

H61366

Grain Tank and Unloading System

Adjusting Unloading Auger Drive Cylinder


If the unloading auger drive will not shut off (disengage), or if the belts jump off as they stretch from use, the cylinder rod stop may need adjustment. A belt that has stretched can cause the drive not to shut off. The belt rotating around the belt trap can fold over and make contact with the upper sheave. To adjust the stop: CAUTION: Set parking brake, shut off engine and remove key. Mark present stop position on rod with tape (A). Loosen nut (B) to relieve spring tension. Loosen bolts (C) and slide stop (D) toward cylinder 13 mm (1/2 in.). Tighten bolts (C). Tighten nut (B) to its original position.
UN05OCT99

ATape BNut CBolts DStop

NOTE: When installing new belts, adjust stop to its original position (stop positioned against barrel of cylinder with rod fully retracted).

OUO6035,0000085 1909NOV001/1

Replacing Unloading Auger Drive Cylinder


This cylinder is not repairable. However a little oil "weeping" from breather (A) is normal and cylinder replacement may not be required.
ABreather
UN05OCT99

OUO6035,0000086 1909NOV001/1

100-6

101801

PN=310

H61371

H61370

Grain Tank and Unloading System

Vertical Adjustment of Auger Support Stud


NOTE: Periodically check to be sure that the auger fully slides into the stud when the auger is fully retracted. Readjust as needed.
UN31JAN01

Loosen nuts (A) to adjust position of stud plate (B). Stud (C) should be vertically centered in hole in auger. Tighten nuts.
AHardware BPlate CStud

OUO6075,000153B 1922FEB011/1

Adjust Swing Cylinder Eyebolt


1. With hydraulic cylinder fully retracted, check gap between plate (A) and stop (B). The gap should be 1216 mm (1/25/8 in).
Specification Plate to StopGap .................................................................. 1216 mm (1/25/8 in)
UN21MAY99

APlate BStop

OUO6075,000153A 1922FEB011/2

2. If gap is incorrect adjust cylinder rod end (A). Loosen jam nut (B) and set screw (C). Screw cylinder rod in or out to obtain correct gap. 3. Tighten jam nut and set screw.
ACylinder Rod End BJam Nut CSet Screw
UN30JAN01

OUO6075,000153A 1922FEB012/2

100-7

101801

PN=311

H66021

H54581

H66020

Grain Tank and Unloading System

Reduced Speed Unloading System (Optional)


Changes the speed of the unloading system by reducing the grain tank cross auger base speed from 411 to 300 rpm. Recommended for use in high volume crops/high moisture crops where bridging or compaction can occur. It is also recommended for use with the double flighted vertical unloading auger option.
UN18MAY01

OUO6075,00016C5 1916MAY011/1

100-8

101801

PN=312

H68076

Fuels and Lubricants


Diesel Fuel
Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. Diesel fuels specified 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 -20C (-4F) or elevations above 1500 m (5000 ft). Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5C (9F) below the expected low temperature. 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 oil and filter 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. DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

DX,FUEL1 1924JAN001/1

Storing Fuel
If 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.

DX,FUEL 1903MAR931/1

105-1

101801

PN=313

Fuels and Lubricants

Fill Fuel Tank


CAUTION: Handle fuel with care: It is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine. Fill fuel tank outdoors. Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.
UN23AUG88

OUO1035,00002A6 1920SEP001/1

105-2

101801

PN=314

TS202

Fuels and Lubricants

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 -37C (-34F). 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 meet 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 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37C (-34F). 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 a supplemental coolant additive. If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.

DX,COOL3 1905FEB991/1

105-3

101801

PN=315

Fuels and Lubricants

Liquid Coolant Conditioner


John Deere Liquid Coolant Conditioner is recommended for wet-sleeve diesel engines not having a coolant filter option. Other conditioners may be used if it contains non-chromate inhibitors. IMPORTANT: If engine is equipped with a John Deere Coolant Filter Conditioner, the correct inhibitors are contained in the filter. If both are used, a gel-type deposit is created which could inhibit heat transfer and block coolant flow. John Deere Liquid Coolant Conditioner does not protect against freezing. Various sizes of coolant conditioners are available from your John Deere dealer.

DX,COOL1 1904JUN901/1

Diesel Engine Break-In Oil


New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level. Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine. After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL. If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation: API Service Classification CE ACEA Specification E1 After the break-in period, use John Deere PLUS-50 or other diesel engine oil as recommended in this manual. IMPORTANT: Do not use PLUS-50 oil or engine oils meeting API CH-4, API CG4, API CF4, ACEA E3, or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.

PLUS-50 is a registered trademark of Deere & Company.

DX,ENOIL4 1924JAN001/1

105-4

101801

PN=316

RG4690

UN14DEC88

Fuels and Lubricants

Diesel Engine Oil


Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oil is preferred: John Deere PLUS-50 The following oil is also recommended: John Deere TORQ-GARD SUPREME
UN10OCT97

Other oils may be used if they meet one or more of the following: API Service Classification CH-4 API Service Classification CG-4 API Service Classification CF-4 ACEA Specification E3 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 is a registered trademark of Deere & Company. TORQ-GARD SUPREME is a registered trademark of Deere & Company

DX,ENOIL 1924JAN001/1

Extended Diesel Engine Oil Service Intervals


When John Deere PLUS-50 oil and the specified John Deere filter are used, the service interval for engine oil and filter changes may be increased by 50%. If other than PLUS-50oil and the specified John Deere filter are used, change the engine oil and filter at the normal service interval.

PLUS-50 is a trademark of Deere & Company

DX,ENOIL6 1910OCT971/1

105-5

TS1661

101801

PN=317

Fuels and Lubricants

Hydrostatic Drive System, Main Hydraulic 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.
SAE 10W engine oils, if they meet API Service Classification CD or CE. John Deere Low Viscosity HY-GARD Transmission/Hydraulic Oil J20 B.

HY-GARD is a trademark of Deere & Company.

OUO1035,00002A7 1920SEP001/1

Transmission, Final Drives, Feeder House Reverser, Dual-Range Cylinder Drive, Primary Countershaft and Loading Auger Elevator
John Deere API GL-5 80W 90 Gear Lubricant is recommended. If other oils are used, they must meet requirements of: API Service Classification GL-5 Military Specification MIL-L-2105B Military Specification MIL-L-2105C Depending on the expected prevailing temperature for the fill period, use oil of viscosity as shown in the chart.
Product Number TY6252 TY6296 TY6256 TY6345 Description 80W/90 GL5 Gear Lube 80W/90 GL5 Gear Lube 85W/140 GL5 Gear Lube 85W/140 GL5 Gear Lube Size 16 kg pail (35 lb. pail) 0.9L (1 qt.) can 16 kg pail (35 lb. pail) 0.9L (1 qt.) can Pkg. Qty. 1 12 1 12
1928NOV90

HX,AG,SF7035 1909OCT911/1

105-6

101801

PN=318

TS245

Fuels and Lubricants

Straw Walker Gearcase


John Deere CORN HEAD GREASE is recommended for the straw walker gear case. You may also use SAE Multipurpose Grease with Extreme Pressure (EP) Performance and meeting NLGI Consistency Number 0.

AG,OUO6435,478 1919NOV991/1

Grease
Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following grease is recommended: John Deere SD POLYUREA GREASE (TY6341) Other greases may be used if they meet the following: NLGI Performance Classification GC-LB IMPORTANT: John Deere SD POLYUREA GREASE (TY6341) is the required grease for the feeder house torque sensing cams. Some types of grease thicken and are not compatible with others. If grease fitting is missing, replace immediately. Clean fittings thoroughly before using grease gun.
Product Number
TY6341

Description
Multi-Purpose, High-Temperature Extreme Pressure Grease, especially effective in rolling contact applications.

HX,AG,SF7350 1926OCT991/1

105-7

TS1667
101801

UN30JUN99

PN=319

Fuels and Lubricants

Brake Fluid
IMPORTANT: When removing reservoir cap, keep contaminants from entering the reservoir. Fluid should be 6 mm (1/4 in.) from top. Fill reservoir with SAE J1703d, DOT-3 or DOT-4 hydraulic brake fluid.

OUO6075,0001758 1930MAY011/1

Lubricant Storage
Your equipment can operate at top efficiency only when clean lubricants are used. Use clean containers to handle all lubricants. 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 accumulation. Make certain that all containers are properly marked to identify their contents. Properly dispose of all old containers and any residual lubricant they may contain.

DX,LUBST 1918MAR961/1

Alternative and Synthetic 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 oils. Rerefined base stock products may be used if the finished lubricant meets the performance requirements.

OUO6075,0001759 1930MAY011/1

105-8

101801

PN=320

Fuels and Lubricants

Capacities
Fuel Tank
Cooling system (with heater) (9540)
Cooling system (with heater) (9560, 9580, 9640)
Cooling system (with heater) (9660, 9680)
Engine Crankcase w/Filter:
9540 Combine
9560, 9580, 9640, 9660, 9680 Combines
Transmission
Final Drives (Each)
Single Reduction
Heavy Duty
Feeder House Reverser Gear Case (Standard)
Feeder House Reverser Gear Case (High Cap.)
Countershaft Drive Gear Case
Straw Walker Drive Gear Case
Loading Auger Gear Case
Dual-Range Cylinder Drive Gearcase
Engine Gearcase
Hydraulic/Hydrostatic Reservoir

565 L (150 gal.)


36 L (38 U.S. qts.)
40 L (42 U.S. qts.)
45 L (48 U.S. qts.)

18.9 L (20 U.S. qts.)


28.5 L (30 U.S. qts.)
9.6 L (10 U.S. qts.)

8.5 L (9 U.S. qts.)


3.8 L (4 U.S. qts.)
0.9 L (2 U.S. pts.)
3.5 L (7.4 U.S. pts.)
1.2 L (2-1/2 U.S. pts.)
400 cc (14 oz)
3.8 L (4 U.S. qts.)
1.9 L (2 U.S. qts.)
16 L (17 U.S. qts.)
34 L (36 U.S. qts.)

OUO6075,0001924 1928JUN011/1

105-9

101801

PN=321

Lubrication and Maintenance


Service During the Break-In Period (First 100 Hours)
Perform service daily or once every 10 operating hours (See Fuels and Lubricants section). Do not idle the engine unnecessarily. Check drive belts and adjust if necessary. Check coolant temperature regularly. Check engine oil and coolant level frequently. Look for signs of leaks. If it becomes necessary to add engine oil during the break-in period, add ENGINE BREAK-IN Oil (See Fuel and Lubricants section).

AG,OUO1035,1510 1920JAN001/1

Service Intervals
CAUTION: To prevent injury, never lubricate or service combine, header, or engine while it is running. Engine must be off, park brake set and key removed. Use hour meter as a guide when servicing the combine. Every 50 hours of engine operation, the characters SEU will appear on the tachometer display indicating service is needed. After completing the service, clear the display by the following procedure. Turn the key to the run position. Press the diagnostic switch. DIA will appear on the triple display tachometer.
UN23MAY01

Continued on next page

OUO6075,000175A 1930MAY011/3

110-1

101801

PN=322

H68150

Lubrication and Maintenance


Press the up arrow switch once to obtain the SEU display. SEU and CLr? will appear on the display.

Continued on next page

OUO6075,000175A 1930MAY012/3

110-2

PN=323

H54584
101801

UN27MAY99

Lubrication and Maintenance


To clear the SEU display: Press the enter switch. SEU and donE will be displayed. Press escape switch once to return to normal operation. The service interval timer can also be reset if service is performed between 45 and 50 hours. IMPORTANT: The service times are for average conditions. Service more often if combine is used in extreme conditions.

OUO6075,000175A 1930MAY013/3

110-3

PN=324

H54585
101801

UN27MAY99

Lubrication and Maintenance

Lubrication Symbols
CAUTION: Never lubricate or service corn head while combine engine is running. Lubricate with John Deere Multipurpose SD Polyurea Grease High Temperature/Extreme Pressure lubricant or an equal SAE Multipurpose High Temperature Grease with Extreme Pressure (EP) performance at hours shown on the symbol.
Lubricate with John Deere SAE 30 oil or heavier oil at hourly intervals indicated on the symbols. IMPORTANT: Recommended service intervals are for average conditions. Service MORE OFTEN if combine is operated under adverse conditions.

HX,AG,SF7039 1914AUG971/1

110-4

101801

PN=325

Lubrication and Maintenance

10 Hours or Daily

AStone Trap BConcave Control Switch

CA/C Drain Hose

DPivot Bolts

EPivot Bolts

1. At the end of each day, dump stone trap (A) and run concave (B) up and down to prevent crop buildup in concave area. IMPORTANT: Pump two shots of grease into each fitting. Do not over grease. 2. Final Drive Outer Bearings (Both Sides)- When operating in mud and water, grease at 10 hours. In normal conditions, grease at 50 hours.

3. Rear Wheel Hubs (Both Sides)- When working in water and mud, grease at 10 hours. In normal conditions, grease at 50 hours.

Continued on next page

OUO6075,000192E 1903JUL011/2
101801

110-5

H69040

UN24JUL01

PN=326

Lubrication and Maintenance


NOTE: When operating in mud and water grease rear axle spindle bearings and motor pivots at 10 hours. In normal conditions grease at 50 hours.
4. Motor Pivots 2-Speed 4-Wheel Drive (both sides). Lube two fittings. 5. Air Conditioning Drain Hose. Clean air conditioning drain hose (C). 6. Tighten feeder house pivot bolts (D and E) to specification. (See Adjusting Fore/Aft Tilt Frame).

OUO6075,000192E 1903JUL012/2

110-6

101801

PN=327

Lubrication and Maintenance

10 Hours or Daily

ADipstick BLower Sight Glass

CUpper Sight Glass

DCoolant Low Mark

EMoisture Sensor

1. Engine oil - Check oil level at dipstick (A). Do not operate engine with oil level below ADD mark. Add oil as needed. 2. Hydrostatic/Hydraulic Oil - Check with header on ground. Oil level must be above lower sight glass (B) and below top of upper sight glass (C). Add oil as needed.

3. Recovery Tank - Check coolant level with engine cold, level must be up to the COLD mark (D). 4. Moisture Sensor. Clean out moisture sensor (E) when operating in weedy or green crops. In normal conditions cleanout at 50 hours.

OUO6075,000192F 1903JUL011/1

110-7

H69041

UN25JUL01

101801

PN=328

Lubrication and Maintenance

50 Hours or Weekly

1. Cleaning Fan Variable Sheaves. 2. Rear Axle Spindles - Standard Axle (Both Sides).

hours. In normal conditions grease at 50 hours.


3. Motor Pivots and 2-Speed 4-Wheel Drive (both sides). Lube two fittings.

NOTE: When operating in mud and water grease rear axle spindle bearings and motor pivots at 10

OUO6075,0001930 1903JUL011/1

110-8

H69042

UN03JUL01

101801

PN=329

Lubrication and Maintenance

50 Hours or Weekly

APlug

1. Fuel System Water Separator - Check for water. Loosen plug (A) and drain. 2. Check cleaning shoe/straw walker drive belt tension. 3. Mass Flow Sensor. Lower auger and clean mass flow sensor plate. 4. Cylinder Variable Drive Upper Sheave - Grease with sheaves closed. Cycle cylinder speed to

distribute grease if drive is operated at high speed all the time. 5. Moisture Sensor. Remove cover and clean out moisture sensor. 6. Cylinder Drive (to places).

OUO6075,0001931 1903JUL011/1

110-9

PN=330

H69043
101801

UN25JUL01

Lubrication and Maintenance

50 Hours or Weekly

AKnob

BWing Nut

CRadiator

DDipstick

1. Unloading Auger Lubrication Lines. 2. Fresh Air Filter-To remove filter, loosen knob (A), remove door and empty tray. Remove wing nut (B) and slide filter out. Clean or replace filter. This filter may require cleaning sooner in very dusty conditions. Clean filter in the same manner as engine primary filter (See Engine Service in this manual).

3. Radiator (C), Charge Air Cooler, Oil Cooler and Condenser Core-Blow compressed air from inside out. Check areas for chaff buildup and clean if necessary. 4. Engine Gear Case-Check with engine off. Oil must not be below mark on dipstick (D).

OUO6075,0001932 1903JUL011/1

110-10

H69044
101801

UN03JUL01

PN=331

Lubrication and Maintenance

50 Hours or Weekly

ACleanout Areas

(HEADERTRAK) only: Check areas (A) for packed material which could prevent header from tilting completely to either side. Clean out if required.

OUO6075,0001933 1903JUL011/1

110-11

H69045

UN03JUL01

101801

PN=332

Lubrication and Maintenance

50 Hours or Weekly (HILLMASTER II Only)

1. Master Cylinder Piston Rod - Until grease comes out. 2. Leveling Cylinder Barrel - Until grease comes out (Both Sides)

3. Final Drive Pivot - Until grease comes out (Both Sides).

OUO6075,0001976 1924JUL011/1

110-12

H69418
101801

UN24JUL01

PN=333

Lubrication and Maintenance

100 Hours

AFilter

BHandle

CDipstick

DValve

IMPORTANT: Change oil every 100 hours if fuel is more than 0.5 % sulfur. Change oil every 250 hours when using all other oils. Change oil every 375 hours when using TORQ-GARD SUPREME or John Deere PLUS-50 Do not operate engine with oil level below low mark on dipstick.

1. Engine Crankcase Filter-Remove old filter (A) and coat seal on new filter with oil. Hand tighten then tighten 1/2 turn more. Turn handle (B) to drain oil. (after first 100 hours only). Pull cap to fill. Check oil at dipstick (C) after filling . 2. Clean out end of air conditioning drain hose. Be certain valve (D) is installed on end of hose. 3. Chopper Bearings. Both sides.

TORQ-GARD SUPREME is a trademark of Deere & Company PLUS-50 is a trademark of Deere & Company

OUO6075,0001934 1903JUL011/1

110-13

101801

PN=334

H69046

UN31JUL01

Lubrication and Maintenance

200 Hours

ASight Glass

1. Recirculating Filter-Remove cooling compartment, reach in and lift out filter. Clean or replace filter. Check to be certain air flow arrow points toward front of combine. 2. Conveyor Auger Drive Slip Clutch-Do not over grease.

3. Reverser Gear Case-Raise feeder house and lower safety stop. Oil level must show on knurled part of dipstick. Add oil as needed.

Continued on next page

OUO6075,0001935 1903JUL011/2
101801

110-14

PN=335

H69047

UN25JUL01

Lubrication and Maintenance


4. Air Conditioning Sight Glass-If there are bubbles in the sight glass (A) after the compressor has run for 30 seconds or more, see your John Deere dealer. 5. Rear Axle (2 places).

OUO6075,0001935 1903JUL012/2

200 Hours

1. Engine Fan Hub 2. Check front and rear tire pressure and wheel bolt torque (see Wheels, Axles and Additional Weights section).

OUO6075,00019DC 1909AUG011/1

110-15

H70142

UN16OCT01

101801

PN=336

Lubrication and Maintenance

250 Hours or Yearly

AFilter

BHandle

CDipstick

1. Engine Crankcase Filter-Remove old filter (A) and coat seal on new filter with oil. Hand tighten then tighten 1/2 turn more. Turn handle (B) to drain oil.

Pull cap to fill. Check oil at dipstick (C) after filling.

Continued on next page

OUO6075,0001AF3 1916OCT011/2

110-16

H70141

UN16OCT01

101801

PN=337

Lubrication and Maintenance


IMPORTANT: Change oil every 100 hours if fuel is more than 0.5% sulfur. Change oil every 250 hours when using all other oils. Change oil every 375 hours when using TORQ-GARD SUPREME or John Deere PLUS-50 . IMPORTANT: Do not operate engine with oil level below low mark on dipstick.

TORQ-GARD SUPREME is a trademark of Deere & Company. PLUS-50 is a trademark of Deere & Company.

OUO6075,0001AF3 1916OCT012/2

110-17

101801

PN=338

Lubrication and Maintenance

400 Hours or Yearly

AVent Plug

BGrease Fitting

CGrease Fitting

Lubricate Intermediate Drive IMPORTANT: Do this with the cylinder speed adjusted to the fastest setting. Start the combine and engage the separator. Increase threshing cylinder to the highest speed. This will compress the spring and reduce the inner cavity to its smallest area. Shut off engine, set park brake and remove key. If you have the cylinder spring at the slowest speed, the tension spring is expanded allowing the inner area to take more grease. If this cavity is completely full, the sheaves cannot come together (creating a hydraulic lock) and increased cylinder speed cannot be attained.

Remove the vent plug (A) from intermediate cylinder drive. Pump grease into grease fitting (B) until grease comes out of the vent plug hole. Install the vent plug. Start the combine and cycle the cylinder from high speed to low speed and back to high speed. Shut off combine. Remove vent plug. Pump grease into grease fitting (C), until grease comes out of vent plug hole. Install vent plug.

OUO6075,0001937 1903JUL011/1

110-18

101801

PN=339

H58391

UN21JUN99

Lubrication and Maintenance

400 Hours or Yearly

APlug

1. Cylinder Drive Bearing 2. Dual Range Cylinder Drive Bearing. Dual Range Cylinder Drive Gear Case-Check oil level. Arrow must point up to check oil at plug (A). Oil must come to bottom edge of plug hole.

3. Primary Countershaft Bearing. 4. Right-Hand Lube Bank (Two Fittings): Top-Cylinder shaft bearing. Bottom-Variable cylinder bearing.

OUO6075,0001938 1903JUL011/1

110-19

101801

PN=340

H69050

UN25JUL01

Lubrication and Maintenance

400 Hours or Yearly

1. Rear Wheel Hubs (Both Sides) (Standard Axle)When operating in mud and water, grease at ten hours.

2. Fan Bearing (Both Sides). 3. Beater Bearing.

HX,AG,SF7052 1918JUN991/1

110-20

H69051
101801

PN=341

1909JUL01

Lubrication and Maintenance

400 Hours or Yearly

1. Tailings Auger Slip Clutch. 2. Secondary Countershaft.

3. Cylinder Drive (two places).

OUO6075,0001939 1903JUL011/1

110-21

101801

PN=342

H69052

UN03JUL01

Lubrication and Maintenance

400 Hours or Yearly

AFill Hole

BCheck Hole

CPlug

1. Rear Axle (Both Sides). Power steering outer fitting. Rear Axle (Both Sides). Power steering inner fitting. Rear Axle (Both Sides). Tie rod fitting. 2. Final Drive Oil. Fill at hole (A). Check oil level up to within 12 mm (1/2 in.) of bottom of hole at plug (B).

(If you can touch oil with your little finger, you do not need to add oil). 3. Transmission. Remove plug (C) and check. Add as needed to within 12 mm (1/2 in.) of bottom of hole.

OUO6075,000193A 1903JUL011/1

110-22

H69053
101801

PN=343

UN03JUL01

Lubrication and Maintenance

400 Hours or Yearly

1. Left-Hand Lube Bank Grease two fittings: Cylinder Shaft Bearing

Beater Shaft Bearing 2. Secondary Countershaft.

OUO6075,000199B 1901AUG011/1

110-23

H69054

UN01AUG01

101801

PN=344

Lubrication and Maintenance

400 Hours or Yearly

1. Reel Speed Valve Spool. 2. Unloading Auger Upper Gear Case.

3. Straw Chopper Rotor Bearings (Both Sides). 4. Unloading Auger Lower Gear Case.

OUO6075,000193C 1903JUL011/1

110-24

H69055

UN01AUG01

101801

PN=345

Lubrication and Maintenance

400 Hours or Yearly

ABrake Fluid

BMain Hydraulic/Hydrostatic Filter

CHydrostatic Charge Filter

1. Conveyor Auger Drive Bearings-Two fittings. 2. Final Drive Outer Bearings (Both Sides)- When operating in mud and water, grease at 10 hours.

3. Brake Fluid Level (A). Look through cap. Add brake fluid to 6 mm (1/4 in.) from top. Do not let dirt get into brake fluid.

Continued on next page

OUO6075,000193D 1903JUL011/2
101801

110-25

H69056

UN03JUL01

PN=346

Lubrication and Maintenance


4. Main Hydraulic/Hydrostatic Filter (B). It is not necessary to drain the reservoir to change this filter. Coat seal on new filter with oil . Hand tighten then tighten 1/2 turn more. 5. Straw Chopper Drive Countershaft Bearings. 6. Straw Chopper Drive Sheave. 7. Hydrostatic Charge Filter (C)- Coat seal on new filter with oil. Hand tighten then tighten 1/2 turn more.

OUO6075,000193D 1903JUL012/2

110-26

101801

PN=347

Lubrication and Maintenance

400 Hours or Yearly

AEngine Gearcase Filter

BPrimary Countershaft Gear Case

CPlug

1. Engine Gearcase Filter (A)-Coat seal on new filter with oil. Hand tighten then tighten 1/2 turn more. 2. Primary Countershaft Gear Case (B)- Check with engine off. IMPORTANT: Do not add water in freezing weather unless engine is run or batteries charged for 30 minutes so water and electrolyte are well mixed.

3. Batteries-Clean off top of batteries and check level in each cell. Fill to bottom of filler neck with distilled water if needed. Clean and tighten connections, if needed. Wipe batteries with damp cloth. When finished, destroy cloth.

Continued on next page

OUO6075,000193E 1903JUL011/2
101801

110-27

H69057

UN03JUL01

PN=348

Lubrication and Maintenance


4. Loading Auger Gear Case-Check plug (C) and add oil as needed.

NOTE: Loading Auger Gear Case does not need to be drained.

OUO6075,000193E 1903JUL012/2

800 Hours or Every Two Years

ARadiator Drain

Drain radiator at (A), flush and refill with the correct coolant and conditioner. See Flushing Cooling System

in Engine Service and Engine Coolant recommendations given in FUELS AND LUBRICANTS.

OUO6075,000193F 1903JUL011/1

110-28

H69059

UN06JUL01

101801

PN=349

Lubrication and Maintenance

2000 Hours

After every 2000 hours of operation have engine valve lash checked, and adjusted if necessary, by your John Deere dealer.

OUO6075,0001941 1903JUL011/1

110-29

H69060

UN03JUL01

101801

PN=350

Lubrication and Maintenance

2000 Hours

APlug BDipstick CFill Hole

DDrain Hole EDrain Hole FCheck Hole

GFill Hole HTube

IBlock JCheck Hole

1. Primary Countershaft Gear Case-Drain at plug (A) and refill at dipstick (B). Oil level must show on knurled part of dipstick. 2. Reverser Gear Case-Raise feeder house and lower safety stop. Drain at (D) and refill at (C). Check with feeder house all the way up. Oil level must show on knurled part of dipstick.

3. Final Drives-Drain at (E) and refill at (G) to within 12 mm (1/2 in.) of bottom of check hole (F). (If you can touch oil with your little finger, you do not need to add oil). 4. Transmission-Slide tube (H) out of block (I). Remove block to drain. Fill at hole (J) to within 12 mm (1/2 in.) of bottom of hole.

OUO6075,0001942 1903JUL011/1

110-30

H69061

UN03JUL01

101801

PN=351

Lubrication and Maintenance

2000 Hours

ADrain Hole BCap

CPlug DSump

ETube

FPlug

1. Hydraulic/Hydrostatic ReservoirDrain at (A). Clean screen and cap (B) and refill. Oil must show above lower sight glass and below top sight glass. 2. Engine Gear CaseDrain at plug (C). Clean breather on dipstick. Clean screen in sump at (D). Refill at tube (E).

3. Dual Range Gear CaseDrain at plug (F). Add oil and check level with arrow up. Do not get oil on belts.

OUO6075,0001943 1903JUL011/1

110-31

H69062

UN20SEP01

101801

PN=352

Lubrication and Maintenance

As Required

AWindshield Washer Reservoir

1. Recirculating Filter-Remove cooling compartment, reach in and lift out filter. Clean or replace as needed. Make sure air flow arrow points towards front of cab. 2. Cab Fresh Air Filter. Turn knob and pull out tray. Remove wing nut and pull out filter. Clean or replace as needed.

3. Windshield Washer Reservoir (Optional) (A). Open cap and fill as needed.

OUO6075,0001944 1903JUL011/1

110-32

H69063

UN03JUL01

101801

PN=353

Lubrication and Maintenance

As Required

AFuel Filter BWater Separator Filter

CPrimary Filter

DWarning Light

EAlternator Screen

1. Fuel Filter. Replace filter (A), water separator filter (B) and bleed system. 2. Batteries. Clean off top of batteries and check level in each cell. Fill to bottom of filler neck with distilled water. 3. Air Cleaner Element. Service primary filter (C) only when shown by warning light (D). Check precleaner

for plugging. Check for leaks and for collapse of aspirator tube. Replace element if plugged. 4. Alternator Screen. Clean alternator screen (E) when 50% covered with debris.

OUO6075,0001945 1903JUL011/1

110-33

H69064

UN01AUG01

101801

PN=354

Lubrication and Maintenance

Replace Engine Crankshaft Damper4500 Hours or Five Years


IMPORTANT: The vibration damper assembly is not repairable and should be replaced every five years or 4500 hours, whichever occurs first. Have your John Deere dealer replace the engine crankshaft damper.

OUO6075,00019E3 1909AUG011/1

Cleaning Combine
Cleaning outside of machine: Wash outside of machine using power washer. Use soft absorbent cloth to wipe off water droplets. Remove excess with clean dry cloth. Use a good clear wax or glazing compound that contains no abrasives and lint free towel. To apply wax or compound: Put compound on cloth and rub into panel in a circular motion after compound is rubbed into the surface well, turn the towel over and buff out with the other (dry) side. Cleaning plastic parts: Cleaning Fabric: Remove dust and loose dirt with whisk broom or vacuum cleaner. Remove excess staining material by scraping or wiping with clean cloth. Clean surfaces with clean, soft damp cloth. For more thorough cleaning wipe surface with soft cloth and mild detergent.

NOTE: Do not clean plastic parts with fuel or other petroleum based cleaners. NOTE: Always follow manufacturers directions when using cleaner and test on a small hidden area first.
Some of machines trim parts are plastic. Use tar and road oil remover to remove dirt, wax buildup and other deposits. Vinyl and Plastic: Remove dust and dirt with a whisk broom or vacuum cleaner. Clean vinyl surfaces with leather and vinyl cleaner.

NOTE: Always follow manufacturers directions when using fabric cleaner and test on a small hidden area first.
For water soluble stain use a damp cloth first, followed by a soft cloth with a mild detergent and water. For grease, oil, tar or other petroleum based stains apply fabric cleaner to soiled following manufactures directions.

OUO6075,0000130 1901DEC001/1

110-34

101801

PN=355

Shields
Left-Hand and Right-Hand Gull Wing Doors
CAUTION: Turn off engine, set parking brake and remove key.
UN25JAN01

To open left-hand door remove locking latch, and pin (A) from locking plate (B). Reinstall locking latch (C) onto pin. Turn latch knob (D) clock-wise, then pull out on gull wing door to raise.
APin BLocking Plates CLocking Latch DLatch Knob

Left-Hand Front Corner

Left-Hand Gull Wing Door

Continued on next page

OUO6075,00018FF 1928JUN011/3

115-1

101801

PN=356

H64206

UN12JUN00

H68542

UN06JUN01

H65931

Shields
To open right-hand gull wing door, remove locking latch and pin (A) from locking plate (B). Reinstall locking latch (C) into pin. Turn latch knob (D) clock-wise, then pull out on gull wing door to raise.
APin BLocking Plate CLocking Latch DLatch Knob

Right-Hand Gull Wing Door

Continued on next page

OUO6075,00018FF 1928JUN012/3

115-2

101801

PN=357

H64207

UN12JUN00

H68543

UN06JUN01

H65929

UN25JAN01

Shields
IMPORTANT: Do not use the cylinder (A) as a hand hold or hang anything on these cylinders. This could cause the cylinder rod to deflect and cause damage to the cylinder. In cold weather or in high winds, these gull wing doors may creep down. Position stop on rod to hold shield up.
ACylinder
UN02MAR00

OUO6075,00018FF 1928JUN013/3

Right-Hand Rear Shield


CAUTION: Turn off engine, remove key and set parking brake.
UN18MAY01

Turn lock (A) to open shield.


ALock

OUO6075,00016C8 1916MAY011/1

115-3

101801

PN=358

H68080

H62860

Shields

Left-Hand Side Separator Shields


Remove cap screw and lock nut from shield (A). Remove shield (B) forward and remove shield (C).
UN18JUL01

Slide shield (D) forward.


AShield BShield CShield DShield

OUO6075,000196C 1918JUL011/1

Right-Hand Side Separator Side Shield


Remove cap screw and lock nut from shield (A), shield (B) and remove shields. Remove cap screw (C) and slide shield (D) rearward
AShield BShield CCap Screw DShield
UN18JUL01

OUO6075,000196D 1918JUL011/1

115-4

101801

PN=359

H69356

UN18JUL01

H69355

H51902

UN04FEB99

H69354

Shields

Cleaning Composite Panels


NOTE: To repair composite panels see your John Deere dealer.
Wash outside of machine using power washer. Use soft absorbent cloth to wipe off water droplets. Use a good clean wax or glazing compound that contains no abrasives and a lint free towel. To apply wax or compound: Put compound on cloth and rub into panel in a circular motion after compound is rubbed into the surface well, turn the towel over and buff out with the other (dry) side.

AG,OUO1035,2160 1931MAY001/1

115-5

101801

PN=360

Service - Engine
Rear Ladder and Landing
Push up on lever (A) and swing ladder out until it latches. Use handle (B) to pull ladder to rear. Swing panel (C) rearward.
ALever BHandle CPanel
UN01MAR99

OUO1035,00002B9 1920SEP001/1

Engine Compartment Door


Raises forward against grain tank to service engine. Prop door up with strap (A). Lower door when not servicing.
AStrap
UN18MAY01

OUO6075,00016C9 1916MAY011/1

Cleaning Engine Compartment


CAUTION: Dirt, oil, chaff and crop debris in the engine compartment and on the engine is a fire hazard. The direction of wind, the type of crop and its moisture content can all have an effect on where and how much chaff and debris can accumulate. Check and clean this area frequently. Do not clean the engine or the engine compartment with the engine running.

OUO6075,0001900 1928JUN011/1

120-1

101801

PN=361

H68558

UN06JUN01

H68081

H54237

Service - Engine

Belt Shield
CAUTION: Drive belts on engine are enclosed behind a shield. Keep shield in place except to service. Shut off engine, remove key and set parking brake before opening. Remove wing screws (A) to open shield.
AWing Screws

OUO6075,00016CA 1916MAY011/1

Engine Access Panel


From grain tank side, remove screws (A) and lift out panel (B) for access to the front side of the engine.
UN08MAR99

ACap Screws BPanel

HX,AG,SF7072 1901MAR991/1

Fuel System
CAUTION: Escaping diesel fuel under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

HX,AG,SF7073 1923JAN921/1

120-2

101801

PN=362

X9811

UN23AUG88

H54273

H68082

UN18MAY01

Service - Engine

Do Not Modify Fuel System


IMPORTANT: Modification or alteration of the injection pump, injection pump timing, or fuel injectors in ways not recommended by the manufacture will terminate the warranty obligation to the purchaser. See warranty information inside front cover. Do not attempt to service injection pump or fuel injectors yourself. Special training and special tools are required. See your John Deere dealer. John Deere dealers are in violation of their dealership agreement if found to be altering power levels of John Deere equipment. Combine warranty is void if power level is changed from factory specifications. Never steam clean or spray water on a warm injection pump. This could cause damage to pump parts.
UN02APR01

6.8 Liter Engine Injection Pump Shown

8.1 Liter Engine Injection Pump Shown

OUO6075,0001901 1928JUN011/1

Handle Fuel SafelyAvoid Fires


Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.
UN23AUG88

Always stop engine before refueling machine. Fill fuel tank outdoors. Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.

DX,FIRE1 1903MAR931/1

120-3

101801

PN=363

TS202

H67143

H61449

UN08OCT99

Service - Engine

Check Engine Oil


IMPORTANT: It is vital to maintain the engine oil at the correct level to ensure a long service life. Check oil level with combine parked on level ground.

NOTE: The oil should be checked with the dipstick screwed all the way into the holder.
Remove dipstick (A) and check oil level. Oil level should be between the "ADD" and the top of the cross-hatch area on dipstick. If needed, add oil recommended in the Fuel and Lubricants section of this manual. Do not operate engine with oil level below the "ADD" mark on dipstick.
ADipstick

OUO6075,00015C7 1902APR011/1

Fuel Tank and Cap


CAUTION: Handle fuel carefully. Do not refuel the machine while smoking. Turn off engine, remove key and set parking brake before filling tank. Rotary screen is turning when engine is running. Fuel tank cap (A) is not vented. CAUTION: Do not overfill fuel tank. Bodily injury can result from fuel splash back. Leakage can result from expansion of fuel. If the tank is filled too full, then left in direct sunlight or if temperature gets too hot, the tank will overflow.

AFuel Cap

OUO6075,0001902 1928JUN011/1

120-4

101801

PN=364

H67698

UN26APR01

H48132

UN24OCT96

H67106

UN09APR01

Service - Engine

Draining Fuel Tank


Petcock (A) at bottom of fuel tank is used for draining. Close finger tight. Use a clean container when draining to see if fuel is dirty.
APetcock
UN10APR01

OUO6075,0001680 1927APR011/1

Replacing Fuel Filter (9540 Combine Only)


CAUTION: Always shut off engine, remove key and set parking brake before performing maintenance work on fuel filter. Unscrew ring (A) and remove filter element (B). Insert new filter element and retighten ring.
ARing BFilter Element
UN18JUL01

OUO6075,000196E 1918JUL011/1

120-5

101801

PN=365

H69357

H67155

Service - Engine

Replacing Fuel Filter


CAUTION: Always shut off engine, remove key and set parking brake before performing maintenance work on fuel filter. How often filter (A) is changed, depends on how clean the fuel is and how it was stored.
UN04APR01

1. To change filter, disconnect water sensor connector (B) from water separator (C). 2. Remove fuel filter. 3. Remove water separator from fuel filter. 4. Install water separator onto new fuel filter. 5. Install fuel filter. 6. Connect water sensor connector.

NOTE: Hand primer must be pulled all the way up between pumps.
8. Unlock hand primer (E) and pump a minimum of 100 times. 9. Lock hand primer (pull up, then push down). 10. Tighten diagnostic fitting on fuel filter header to specification.
Specification Diagnostic PortTorque ................................................................ 14 Nm (10 lb-ft) AFuel Filter BWater Sensor Connector CWater Separator DDiagnostic Fitting EHand Primer

11. Start engine and run engine at high idle.

OUO6075,00016CB 1916MAY011/1

120-6

101801

PN=366

H67285

UN09APR01

7. Loosen diagnostic fitting (D) on fuel filter header.

H67284

Service - Engine

Water Separator Filter Replacement (9540 Combine Only)


Shut off valve (A).
UN01MAR99

Drain fuel from separator at drain (B). Remove and replace filter. Open valve (A). Let air bleed through (B) and fuel line (C). See BLEEDING FUEL LINES.
AValve BDrain CFuel Line

OUO6075,0001904 1928JUN011/1

Draining Water Separator


When fuel/separator bowl (A) senses water in the fuel system an error code will be displayed. If an error code appears drain fuel/water separator bowl using water drain (B) and clear error code.
ASeparator Bowl BWater Drain

OUO6075,00016CC 1916MAY011/1

Bleeding Fuel Lines


If the engine still will not start after bleeding the filter, it may be necessary to bleed the lines as follows: Use two wrenches to loosen the high pressure line on three injectors. Crank engine over, but do not start engine, until fuel (free of air bubbles) flows out of connections. Tighten connections, start engine and check for leaks.

OUO6075,00016B1 1914MAY011/1

120-7

101801

PN=367

H67143

UN02APR01

H67144

UN02APR01

H54241

Service - Engine

Bleeding Engine Fuel Filter (9540 Combine Only)


Air can enter the fuel system when changing the filter or running out of fuel. Air in the system could prevent engine from starting. Use the following procedure to bleed the filter. Turn key to the on position. Let fuel pump run 3040 seconds to remove air in the fuel system. Repeat if necessary.

OUO6075,0001970 1918JUL011/1

120-8

101801

PN=368

H69358

UN24JUL01

Service - Engine

Bleeding Combine Fuel System


1. Drain water and contaminates from water separator bowl (A) by opening drain (B). 2. Connect JT03472 coupler and hose to diagnostic port (C). If JT03472 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 JT03472 coupler from diagnostic port, or while tightening diagnostic port to specification.
Specification Diagnostic PortTorque ................................................................ 14 Nm (10 lb-ft)
UN04APR01

5. Start engine and run engine at high idle. 6. If engine fails to start, loosen high pressure fuel lines (E). Pump hand primer (D) 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).
Specification High Pressure Fuel Lines Torque ............................................................................................ 27 Nm (20 lb-ft)

7. Start engine. If engine fails to start, repeat step 6.

AWater Separator Bowl BDrain Valve CDiagnostic Port DHand Primer EHigh Pressure Fuel Lines

OUO6075,00016B2 1914MAY011/1

120-9

101801

PN=369

H67288

UN04APR01

H67287

H67144

UN02APR01

Service - Engine

Drain Cooling System


Every two years or 800 hours, drain cooling system by opening drains on radiator (A) and engine block (B).
ARadiator Drain BEngine Block Drain

Continued on next page

OUO6075,00016B3 1914MAY011/2

120-10

101801

PN=370

H49034

UN08AUG97

H67161

UN03APR01

Service - Engine
IMPORTANT: Never pour cold water into a hot engine as it might crack cylinder block or head. Do not operate engine without coolant for even a few minutes.
UN01MAR99

Remove clamp and hose (A) from bottom of recovery tank and drain tank. Close drains, install hose on recovery tank and fill system with clean water. Run engine until it reaches operating temperature with heater on.
AHose

Stop engine and drain water out before rust or sediment settles. Close drains and refill system with a solution of clean water and John Deere Cooling System Cleaner PT500 or its equal. Follow instructions with cleaner. After using cleaner, flush system with clean water and drain. Close drains, close and latch rotary screen door and fill system with correct coolant and conditioner (See the recommendations given in FUELS AND LUBRICANTS in this manual). To fill system: Open breather valve on top of engine. Fill system until fluid begins to run out of breather valve. Close breather valve and finish filling system until fluid is at HOT mark on recovery tank. Install cap on radiator, turn on the heater and run engine until it reaches operating temperature. Remove cap from recovery tank and refill tank to fill mark. Do not fill recovery tank from radiator. Install cap on recovery tank.

OUO6075,00016B3 1914MAY012/2

120-11

101801

PN=371

H54247

Service - Engine

Filling Radiator
CAUTION: Avoid being scalded when radiator cap is removed. First turn cap slightly to the stop. This lets steam safely out the vent. Never fill radiator when engine is overheated unless engine is idling slowly. Pour coolant in slowly. Check coolant level when engine is cold. Check coolant level in recovery tank. When the engine is cool, the coolant level should be up to the COLDmark. IMPORTANT: Never pour cold water into a hot engine as it might crack cylinder block or head. Do not operate engine without coolant for even a few minutes.

HX,AG,SF7088 1909OCT911/1

Winterize Cooling System


IMPORTANT: Do not drain cooling system to protect against freezing. The heater does not drain completely, so damage would result. Before cold weather, be sure the cooling system has enough antifreeze. Use a reliable brand of permanent-type ethylene glycol antifreeze which contains a rust inhibitor and water pump lubricant, but does not contain a leak-stopping additive. See Fuels and Lubricants in this manual for the correct recommendations. After adding antifreeze, turn heater on and run engine until it reaches operating temperature. This mixes the solution and circulates it through the system.

HX,AG,SF7089 1913DEC931/1

120-12

101801

PN=372

H54080

UN19FEB99

Service - Engine

Replacing Engine Fan Belt


CAUTION: Shut off engine, remove key and set parking brake.
UN05APR01

1. Remove bolts (A) and fan (B).


ABolts (6 used) BFan

Engine Fan Bolts

OUO6075,00016D2 1916MAY011/2

2. To remove belt, insert 13 mm (1/2 in.) drive breaker bar (A) into square hole in idler to release tension on belt. 3. Remove belt (B) from alternator. 4. Install new belt in reverse order and tighten fan bolts to specification.
Specification Fan BoltsTorque ......................................................................... 60 Nm (45 lb-ft)
UN05APR01

A13 mm (1/2 in.) Breaker Bar BBelt

OUO6075,00016D2 1916MAY012/2

120-13

101801

PN=373

H67317

H67316

Service - Engine

Engine Accessory Drive Belt Routing (6.8 Liter Engine)


AAlternator BRotary Screen Drive Sheave CRotary Screen/Alternator Sheave DTensioner EAir Conditioning Compressor FFan Belt GSpring Loaded Tensioner HRotary Screen Driven Sheave IRotary Screen Drive Belt JEngine Crankshaft Sheave KSpring Loaded Tensioner LAlternator Belt MWater Pump Sheave NFan Drive Sheave OTensioner

C
E
D

G
N
UN01AUG01

I
J

OUO6075,000199A 1901AUG011/1

Engine Accessory Drive Belt Routing (8.1 Liter Engine)


ASpring Loaded Idler BAlternator CAlternator Belt DWater Pump Sheave EFan Belt FAir Conditioning Compressor GTension Idler HRotary Screen Driven Sheave IRotary Screen Drive Belt JRotary Screen Drive Sheave KEngine Crank Shaft Sheave LSpring Loaded Idler MFan Drive Sheave

B
A
D

E
F

G
L

M
UN10APR01
101801

J
K

OUO6075,00016CE 1916MAY011/1

120-14

PN=374

H67319

H69505

Service - Engine

Replace Engine Accessory Drive Belt


CAUTION: Shut off engine, remove key and set parking brake.
UN05APR01

1. Remove bolts (A) and fan (B).


ABolts (6 used) BFan

Engine Fan Bolts

OUO6075,00016CF 1916MAY011/6

2. To remove alternator belt, insert 13 mm (1/2 in.) drive breaker bar (A) into square hole in idler to release tension on belt. 3. Remove belt (B) from alternator.
A13 mm (1/2 in.) Breaker Bar BBelt
UN05APR01

OUO6075,00016CF 1916MAY012/6

4. Remove nut (A) and loosen nut (B) to relieve spring tensioning. 5. Remove spring pin (C) and washer from tensioning rod. 6. Remove tensioning rod from hole to relieve tension. 7. Remove belt (D).
ANut BNut CSpring Pin DBelt
UN05APR01

Continued on next page

OUO6075,00016CF 1916MAY013/6
101801

120-15

PN=375

H67321

H67317

H67316

Service - Engine
8. To remove engine accessory drive belt, insert a 13 mm (1/2 in.) drive breaker bar (A) into the square hole in idler to release tension on the belt. 9. Remove belt (B). 10. Install engine accessory drive belt in reverse order.
A13 mm (1/2 in.) Breaker Bar BBelt
UN05APR01

OUO6075,00016CF 1916MAY014/6

11. Install rotary screen drive belt (D). 12. Install tensioning rod, washer and spring pin (C). 13. Install and tighten nut (B) until gauge is at the end of spring. 14. Install and tighten nut (A).
ANut BNut CSpring Pin DBelt
UN05APR01

OUO6075,00016CF 1916MAY015/6

15. Install fan (B) and tighten fan bolts (A) to specification.
Specification Fan BoltsTorque ......................................................................... 62 Nm (45 lb-ft)
UN05APR01

ABolts (6 used) BFan

Engine Fan Bolts

OUO6075,00016CF 1916MAY016/6

120-16

101801

PN=376

H67316

H67321

H67322

Service - Engine

Rotary Screen Belt Routing


ARotary Screen BBelt CIdlers DDrive Sheave
UN11OCT88

HX,AG,SF7095 1909OCT911/1

Replacing Rotary Screen Drive Belt


1. Remove bolts (A) and fan (B).
ABolts (6 used) BFan
UN05APR01

Engine Fan Bolts

OUO6075,00016D0 1916MAY011/5

2. To remove alternator belt, insert 13 mm (1/2 in.) drive breaker bar (A) into square hole in idler to release tension on belt. 3. Remove belt (B) from alternator.
A13 mm (1/2 in.) Breaker Bar BBelt
UN05APR01

Continued on next page

OUO6075,00016D0 1916MAY012/5

120-17

101801

PN=377

H67317

H67316

H39170

Service - Engine
4. Remove nut (A) and loosen nut (B) to relieve spring tensioning. 5. Remove spring pin (C) and washer from tensioning rod. 6. Remove tensioning rod from hole to relieve tension. 7. Remove belt (D). 8. Install new belt.
UN05APR01

ANut BNut CSpring Pin DBelt

OUO6075,00016D0 1916MAY013/5

9. Install rotary screen drive belt (D). 10. Install tensioning rod, washer and spring pin (C). 11. Install and tighten nut (B) until gauge is at the end of spring. 12. Install and tighten nut (A).
ANut BNut CSpring Pin DBelt
UN05APR01

Continued on next page

OUO6075,00016D0 1916MAY014/5

120-18

101801

PN=378

H67321

H67321

Service - Engine
13. Install fan (B) and tighten fan bolts (A) to specification.
Specification Fan BoltsTorque ......................................................................... 62 Nm (45 lb-ft)
UN05APR01

ABolts (6 used) BFan

Engine Fan Bolts

OUO6075,00016D0 1916MAY015/5

Cleaning Rotary Screen, Oil Cooler, Condenser, Radiator and Charge Air Cooler
CAUTION: Shut off engine, remove key and set parking brake. Pull latch (A) and open rotary screen door (B).
ALatch BRotary Screen Door
UN02JUL01

Continued on next page

OUO6075,0001906 1928JUN011/2

120-19

101801

PN=379

H68535

H67316

Service - Engine
Check the rotary screen daily to be certain it turns freely. Clean the rotary fan screen with a brush and compressed air when dirt and chaff build up on or behind the screen. Pull oil cooler and condenser (A) out. Clean oil cooler, condenser and radiator. Clean charge air cooler. To clean with compressed air, blow from the inside out. Clean out dirt from lower vacuum duct (B) and duct (C). IMPORTANT: When using high pressure air or water, be careful of fin damage to coolers. Use a fin comb to straighten bent fins. Bent fins will decrease cooler performance.
ACondenser BVacuum Duct CDuct
UN21MAY01

OUO6075,0001906 1928JUN012/2

Adjust Rotary Screen Knife Comb


Loosen nuts (A) and position knife comb so rake bar (B) passes through comb without interference.
ANuts BRake Bar

HX,AG,SF7099 1902MAR991/1

120-20

101801

PN=380

H54250

UN01MAR99

H68084

Service - Engine

Removing Air Cleaner Filters


IMPORTANT: When servicing filters, turn off engine, remove key and set parking brake so dirt cannot be pulled into engine. Service filters only when engine air filter light stays on. Unsnap dust cover (A) and remove primary air filter (B). The safety filter (C) stops dirt that would pass through a damaged primary filter. Clean, wash or replace the primary filter. Do not clean or wash the safety filter, but install a new one if needed. Do not remove the metal wrap on the filter. IMPORTANT: Never run the engine without both filters in place. Check all connections in the air intake system. Be certain they are tight. IMPORTANT: Do not use any exhaust flow cleaning unit to blow chaff off combine. Using such a unit can cause air filter failure, followed by engine failure.
ADust Cover BPrimary Air Filter CSafety Filter

OUO6075,00016D4 1916MAY011/1

Inspecting Element
1. Hold a bright light inside element (A) and check carefully for holes. Discard any element which shows the slightest hole. 2. Be sure outer screen (B) is not dented. Vibration would quickly wear a hole in filter. 3. Be sure filter gasket (C) is in good condition. If gasket is damaged or missing, replace element.
AElement BOuter Screen CFilter Gasket
UN31AUG99

OUO1035,00002D8 1920SEP001/1

120-21

101801

PN=381

H59771

H59770

UN31AUG99

Service - Engine

Cleaning Element
1. Pat sides of element (A) gently to loosen dirt. Do not tap element against a hard surface. 2. Using a John Deere AR62377 Dry Element Cleaner Gun (B), clean element with compressed air. Hold nozzle next to inner surface, and move up and down pleats. IMPORTANT: Do not direct air against outside of element, as it might force dirt through to inside. 3. Repeat step 1 and 2 to remove additional dirt. 4. Inspect element before reinstalling.
AElement BJohn Deere AR62377 Dry Element Cleaner Gun
UN31AUG99

OUO1035,00002D9 1920SEP001/1

Washing Element
IMPORTANT: Never wash element in gasoline or any solvent. Never use compressed air on a wet element. Do not oil element. 1. If element is coated with oil or soot, wash in a solution of warm water and John Deere R36757 Filter Element Cleaner or its equivalent. Let element soak at least 15 minutes, then agitate gently to flush out dirt. 2. Rinse element thoroughly from inside with clean water. Use element cleaning gun (A) or a free-running hose. Keep pressure low to avoid damaging element. 3. Allow element to dry completely before using. This usually takes from one to three days. Do not oven dry or use drying agents. Protect element from freezing until dry. 4. Inspect element before installing.

AElement Cleaning Gun

NOTE: Primary element can be washed up to six times.

OUO1035,00002DA 1920SEP001/1

120-22

101801

PN=382

H59773

UN31AUG99

H59772

Service - Feeder House


Hydraulic Cylinder Safety Stop
CAUTION: Before performing any service or maintenance on raised feeder house, lower safety stop onto hydraulic cylinder. Shut of engine, set parking brake and remove key. Lower safety stop (A) onto hydraulic cylinder rod.
ASafety Stop
UN21SEP89

OUO6075,0001907 1928JUN011/1

125-1

101801

PN=383

H69336

UN18JUL01

TS696

Service - Feeder House

Replacing Fixed Speed Feeder House Belt

C
A

ANuts

BBelt

CWasher

DGauge

CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key. 1. (Not Illustrated) Remove shields. 2. Loosen nuts (A) to release tension on idlers. 3. Remove belt (B).

4. Install new belt. 5. Tighten nuts until washer (C) aligns with end of gauge (D). 6. Install shields.

OUO6075,0001908 1928JUN011/1

125-2

101801

PN=384

H68115

UN04JUN01

Service - Feeder House

Removing Conveyor Chain Links


First Adjustment (Approximately 500 Hrs): Remove offset links (A) for initial chain adjustment. Second Adjustment (Approximately 1200 Hrs):

NOTE: When replacing chain links always check sprockets for wear. To replace sprockets see procedures later in this group.
Remove inside links (B) and replace them with offset links. Order ([3]) offset links (C). The offset links now becomes the coupler links. Repeat this procedure on all strands of chain. When adjustment is all used up the chain is worn out and should be replaced.
AOffset Links BInside Links COffset Links
UN11OCT88

OUO6075,000198C 1927JUL011/1

Adjusting Feeder Conveyor Drive Chain


Level Land Combine Open front shield. Loosen nut (A) and push sprocket rearward. Loosen nut (B) and move sprocket to center position. Tighten nut (B). Use pry bar in holes of inside plate to move sprocket forward and tighten nut (A). Tighten nut (A) and close shield.
UN21MAY01

ANut BNut

OUO6075,00016D8 1917MAY011/1

125-3

101801

PN=385

H68095

H39621

Service - Feeder House

Adjusting Fixed Speed Feeder House Belt

C
A

ANuts

BBelt

CWasher

DGauge

CAUTION: Raise feeder house, lower safety stop, shut off engine, set parking brake and remove key.

Tighten nuts (A) until washer (C) aligns with end of gauge (D). This will correctly tension belt (B).

OUO6075,0001909 1928JUN011/1

125-4

101801

PN=386

H68115

UN04JUN01

Service - Separator
Adjusting Cylinder Drive Gap
Run cylinder sheaves to close the intermediate sheaves. CAUTION: Shut off engine, remove key and set parking brake. Loosen bolt (A). Adjust nuts (B) to get a 6 mm (1/4 in.) gap. IMPORTANT: If sheave gap is more than 8 mm (5/16 in.), it limits sheave travel. Any of these failures can occur when drive is operated at the high end of either low or high range: Belt failure Belt stretch Bearing failure Shaft failure

ABolt BNuts

If sheave gap is less than 4 mm (3/16 in.), it limits torque sensing. Any of these failures can occur when drive is operated at the low end of either low or high range: Belt failure Belt slipping (burning) Retighten bolt (A).

OUO1035,00002E8 1920SEP001/1

130-1

101801

PN=387

H61193

UN04OCT99

Service - Separator

Aligning Cylinder Drive


CAUTION: Shut off engine, remove key, and set parking brake.
UN04OCT99

Loosen nuts (A) to remove tension from drive belt (B). Loosen countershaft assembly with nuts (C). Loosen cap screw (D). Loosen cap screws (E) and (F). Loosen nuts (G).
ANuts BDrive Belt CNuts DCap Screw ECap Screws FCap Screws GNuts

AG,OUO1035,1110 1911OCT991/3

Using a straight edge (A), check the alignment of the countershaft sheaves to the sheaves on the primary countershaft. The countershaft sheaves should be within +/- 2 mm (1/16 in.) of the primary countershaft. Make adjustments with nuts (B). After making adjustments, tighten nuts (B).
AStraight Edge BNuts

Continued on next page

AG,OUO1035,1110 1911OCT992/3

130-2

101801

PN=388

H61195

UN04OCT99

H61194

Service - Separator
Using a straight edge (A), check the alignment of the countershaft sheaves to the sheaves on the cylinder shaft. The countershaft sheaves should be within 2 mm (1/16 in.) of the cylinder shaft. Make adjustments with nuts (B). After making adjustments, tighten nuts (B). Tighten cap screws (C), (D) and (E). Tighten nuts (F). Readjust cylinder drive gap. (See ADJUSTING CYLINDER DRIVE GAP).
AStraight Edge BNuts CCap Screw DCap Screw ECap Screw FNuts
UN04OCT99

AG,OUO1035,1110 1911OCT993/3

Adjusting Cylinder Belt Idler


CAUTION: Shut off engine, remove key, and set parking brake.
UN04OCT99

Loosen lock nut (A). Tighten nut (B) until washer (C) aligns with the end of gauge (D). Tighten lock nut.
ALock Nut BNut CWasher DGauge

OUO1035,00002EA 1920SEP001/1

130-3

101801

PN=389

H61197

H61196

Service - Separator

Replacing Cylinder Intermediate Belt

AHose BTension

CBolts

DMounting

EBelt

Run cylinder drive to slowest speed. CAUTION: Shut off engine, remove key, and set parking brake. Disconnect hose (A) with two wrenches. Loosen belt at (B).

Remove two bolts (C), swing mounting (D) aside and remove belt (E). Install new belt and check alignment.

130-4

H61198

UN04OCT99

AG,OUO1035,1111 1911OCT991/1

101801

PN=390

Service - Separator

Replacing Cylinder Belt

AHydraulic Hose BJam Nut

CCylinder Belt DCylinder Intermediate Belt

EBolts

FMounting

Run cylinder drive to slowest speed. CAUTION: Shut off engine, remove key and set parking brake. Disconnect hydraulic hose (A). Loosen lock nut and jam nut (B) to loosen cylinder belt (C). Roll cylinder belt (C) under belt (D).

Remove two bolts (E) and swing mounting (F) aside. Remove belt. Install new belt. Adjust cylinder belt. (See ADJUSTING CYLINDER BELT IDLER). Check intermediate belt alignment. (See ALIGNING CYLINDER DRIVE).

130-5

H61199

UN04OCT99

AG,OUO1035,1112 1911OCT991/1

101801

PN=391

Service - Separator

Second Concave Adjustment


Remove locking lever (A). Adjust second concave (B) using handle (C). Adjust turnbuckles to specification (D).

ALocking Lever BSecond Concave CHandle DSpecification (Distance) Item Measurement Specification

Second concave linkage

Distance

220 mm 8 21/32 in.

Lock lever in place with locking lever.

OUO6075,0001971 1918JUL011/1

Adjusting Beater Belt Idler


The beater belt idler is located on the left-hand side of the combine behind the tailings elevator. Tighten nut (A) until washer (B) aligns with the end of gauge (C). Tighten locking nut (D).
ANut BWasher CGauge DLocking Nut

HX,AG,SF7128 1913DEC931/1

130-6

101801

PN=392

H53044

UN15FEB99

ZX25233

UN03JUL01

Service - Separator

Replacing Beater Belt


IMPORTANT: Always replace both belts as a matched set to insure equal wear. Loosen nuts (A) to loosen idler (located behind the tailings elevator) and remove belts (B). Install new belt and adjust idler.
AIdler BBelts

HX,AG,SF7129 1923NOV981/1

Adjusting Secondary Countershaft Belt


Turn nut (A) until block (B) covers hole (C). Tighten jam nut.
ANut BBlock CHole
UN04OCT99

HX,AG,SF7131 1923NOV981/1

130-7

101801

PN=393

H61200

H53046

UN15FEB99

H53045

UN15FEB99

Service - Separator

Replacing Secondary Countershaft Belt


Sound horn, start combine, set engine idle at 1200 rpm, engage separator and increase cylinder speed to maximum, disengage separator, shut off engine, set parking brake and remove key. CAUTION: Lower variable sheave is under spring tension; if belt is removed, it will snap back to a closed position.
UN11JUL97

Place a block of wood in sheave (A) opening to hold sheave apart. Adjust nut so intermediate sheave goes up as far as possible. Belt (B) will have slack. Disconnect hose (C). Loosen secondary countershaft belt (D) at (E). Roll belt under clean grain elevator belt and tailings elevator belt.
Shield Removed for Clarity
ASheave BBelt CHose DCountershaft Belt EIdler

HX,AG,SF7132 1901MAR991/1

130-8

101801

PN=394

H48976

Service - Separator

Replacing Power Separator Belt


Loosen nut (A) to release tension on idler pulley. Remove and replace power separator belt (B) from power separator sheave (C).
ANut BPower Separator Belt CSheave

OUO6075,000190A 1928JUN011/1

Adjusting Feeder House Drive/Reel Pump Belt


Tighten nut (A) until washer aligns with end of gauge.
ANut

OUO6075,0001986 1926JUL011/1

130-9

101801

PN=395

H70107

UN03OCT01

ZX25108

UN01JUN01

Service - Separator

Replacing Feeder House/Reel Pump Belt


IMPORTANT: It is not necessary to disconnect any hydraulic hoses to replace this belt. Remove shields. Remove electric clutch module strap cap screw (A) and disconnect connector (B). Loosen nut (C) on header drive tensioner idler and remove drive belt (D) from electric clutch. Remove fixed speed feeder house belt (see Service Feeder House section). Remove and install new feeder house drive belt in reverse order.
ACap Screw BHarness Connector CNut, Tensioner DBelt
UN04JUN01 UN05MAY99

OUO6075,0001987 1926JUL011/1

Adjusting Straw Walker Gearcase Belt


Loosen locking nut (A). Tighten nut (B) until washer (C) aligns with the end of gauge (D). Tighten locking nut.
ALocking Nut BNut CWasher DGauge
UN03JUL01

OUO6075,0001928 1902JUL011/1

130-10

101801

PN=396

H69073

ZX25097

H56016

Service - Separator

Adjusting Straw Walker Plugging Switch


CAUTION: Straw walkers are sharp. Lay a piece of cardboard or old carpet on walkers before beginning work. If this switch does not turn on light (A) and the buzzer when plugging occurs, clean off the walkers, check switch arm (B) for free movement and clean off if necessary. If the switch still does not work, adjust as follows: Push switch arm (B) up. Loosen two screws (C), set a 2 mm (5/64 in.) (0.080 in.) gap (D) and then tighten screws. A nickel could be used to check this gap. If the switch still does not work, see your John Deere dealer.
ALight BSwitch Am CScrews D2 mm (5.64 in.) Gap

4/4

3/4

OUO6075,000190C 1928JUN011/1

Adjusting Cleaning Shoe Auger Gears


CAUTION: Raise feeder house and lower safety stop.
UN11OCT88

Shut off engine, remove key, and set parking brake. Loosen nut (A) on clamp (B). Adjust gears (C) until they touch. Back clamp (B) off 0.8 mm (1/32 in.) and tighten nut. Do not run gears too tight.
Shield Removed for Clarity
ANut BClamp CGears

HX,AG,SF7137 1923NOV981/1

130-11

101801

PN=397

H39141

H39452

UN15MAY89

H68706

UN12JUN01

Service - Separator

Replacing Cleaning Shoe Belt

ATop Belt

BSpring Tensioner

CBottom Belt

DSpring Tensioner

CAUTION: Engine must be off, key removed and parking brake set. To replace the top belt (A) loosen spring tensioner (B). Roll belt under secondary countershaft belt, tailings belt and clean grain belt. Install new belt in reverse order (see belt routing diagram). Tighten spring tensioner until washer aligns with end of gauge.

To replace the bottom belt (C) loosen spring tensioner (D). Remove top belt from pulley then remove bottom belt. Install new belt in reverse order (see belt routing diagram). Tighten bottom spring tensioner until washer aligns with the end of gauge. Install top belt and tighten spring tensioner.

OUO6075,0001925 1928JUN011/1

130-12

101801

PN=398

H69024

UN27JUL01

Service - Separator

Replacing Cleaning Fan Belt


Start engine, engage separator and operate fan to its fastest speed. CAUTION: Engine must be off, key removed and parking brake set. Disengage separator and shut off engine. Remove cap screws and lock nuts (A) from shields. Slide top shield (B) forward and lower shield (C) rearward. Disengage locking strap (D) and lower shield (E).
ACap Screws and Lock Nuts BTop Shield CLower Shield DLocking Strap ELower Shield

OUO6075,0001683 1927APR011/2

Wedge bottom sheave (A) open. Disconnect front arm (B) and swing out of the way. Remove belt (C) from upper and lower sheave. Install new belt. Reinstall shields.
ABottom Sheave BFront Arms CBelt
UN16FEB99

OUO6075,0001683 1927APR012/2

130-13

101801

PN=399

H53050

UN16FEB99

H53059

H53049

UN16FEB99

H51900

UN28JAN99

Service - Separator

Replacing Clean Grain Elevator Belt


Remove shields. Remove top access doors. Loosen jam nut and adjustment nut (A). Remove belt (B). Install new belt. See routing (C).
AAdjustment Nut BBelt CBelt Routing
UN21JUN99

HX,AG,SF7140 1913DEC931/2

Tighten adjustment nut (A) until gauge (B) aligns with washer (C). Tighten jam nut.
AAdjustment Nut BGauge CWasher

HX,AG,SF7140 1913DEC932/2

Adjust Clean Grain Elevator Drive Belt


Tighten adjustment nut (A) until gauge (B) aligns with washer (C). Tighten jam nut.
AAdjustment Nut BGauge CWasher
UN19MAY99

HX,AG,SF7141 1917MAY991/1

130-14

101801

PN=400

H57358

H57358

UN19MAY99

H55853

Service - Separator

Adjusting Clean Grain Elevator Chain


Loosen nuts (A). Loosen nuts (B) and (C). Adjust nut (B) to adjust chain. Elevator chain is adjusted properly when lower end of chain can be slid across the sprocket or can be pulled 6 mm (1/4 in.) away from the sprocket. Tighten nuts (C) and (A).
UN16FEB99

NOTE: When the clean grain elevator adjustment has reached the end of the slot, remove one full link and add one half link. Removing a full link can result in difficulty in reattaching the chain ends.

ANuts BNuts CNuts

OUO6075,000013F 1901DEC001/1

Replacing Tailings Auger and Elevator Drive Belt


Loosen nuts (A) to loosen idler. Remove belt (B). Install new belt
ANuts BBelt
UN16FEB99

Continued on next page

HX,AG,SF7143 1923NOV981/2

130-15

101801

PN=401

H53060

H53028

Service - Separator
Tighten nut (A) until washer (B) aligns with end of gauge (C).
ANuts BWasher CGauge
UN16FEB99

HX,AG,SF7143 1923NOV982/2

Adjusting Tailings Elevator Belt


Tighten nut (A) until washer (B) aligns with the end of gauge (C).
ANut BWasher CGauge

HX,AG,SF7144 1913DEC931/1

Adjusting Tailings Elevator Drive Chain


Loosen bolt (A) and lower shield. Loosen nut (B) to adjust tightener against chain.
ABolt BNut
UN01MAY00

HX,AG,SF7145 1913DEC931/1

130-16

101801

PN=402

H63765

H53056

UN16FEB99

H53056

Service - Separator

Adjusting Tailings Elevator Paddle Chain


Loosen cap screw (A) and lower shield. Loosen jam nuts (A) and using bolt (B) (both sides of elevator) adjust chain. Elevator chain is adjusted properly when lower end of chain can be slid across the sprocket or can be pulled 6 mm (1/4 in.) away from the sprocket.
Specification ChainDistance ................................................................................ 6 mm (1/4 in.)
UN01MAY00

ACap Screw BJam Nuts CBolt

HX,AG,SF7146 1923NOV981/1

Adjusting Upper Tailings Auger Drive Chain


Loosen bolt (A). Adjust nuts (B) to tighten chain (C).
ABolt BNuts CChain
UN23FEB99

HX,AG,SF7147 1923NOV981/1

130-17

101801

PN=403

H53057

H63766

Service - Chopper and Spreader


Replacing Knife Sections
CAUTION: Engine must be off, key removed and parking brake set.
UN24JUL01

Remove cap screws (A). Remove knife cover (B) to access knife sections. CAUTION: These blades are sharp. Turn knives over for additional usage.
ACap Screws BKnife Cover

HX,AG,SF7148 1923NOV981/1

135-1

101801

PN=404

H69420

Service - Chopper and Spreader

Remove and Replace Straw Chopper Blades


B

IMPORTANT: Replace any broken or damaged blades immediately. A broken blade will unbalance the straw chopper and cause serious damage. 1. Remove lock nut (A), cap screw (B), washer (C) and bushing (L). IMPORTANT: Straw chopper balance MUST be maintained. Eight blades MUST be installed to replace one broken blade. This MUST be done to keep vibration to a minimum. For example: If blade (D) is broken, replace blades (D), (E), (F) and (G) and blades (H), (I), (J) and (K) on the opposite side. 2. Replace blade and install cap screw (B), washer (C), bushing (L) and lock nut (A). Torque nut to specification.
Specification Chopper Blades Lock Nut Torque ............................................................................................ 60 Nm (44 lb-ft)

ALock Nut BCap Screw CWasher DBlade EBlade FBlade GBlade HBlade IBlade JBlade KBlade LBushing

AG,OUO6023,65 1925JUL001/1

135-2

PN=405

H66676
101801

UN12MAR01

Service - Chopper and Spreader

Remove and Replace Counter Knife Bank


CAUTION: Engine must be off, key removed and parking brake set. To prevent personal injury use two service technicians to remove the counter knife bank. Counter knife bank is heavy and knifes are sharp. Wear gloves when replacing counter knife bank. Remove bolts (A and B). Repeat on opposite side. Remove counter knife bank (C) and replace worn or broken chopper blades.
ACap Screw BCap Screw CCounter Knife Bank
UN24JUL01

OUO6075,0001975 1924JUL011/1

Replacing Chopper Belt


Loosen nuts (A) to relieve spring (B) tension.
ANuts BSpring
UN13JUN01

OUO6075,000190D 1928JUN011/3

Remove shield (A and B) to replace belt (C). Install and tighten shields.
AShield BShield CChopper Belt

Continued on next page

OUO6075,000190D 1928JUN012/3

135-3

101801

PN=406

H68717

UN13JUN01

H68716

H69421

Service - Chopper and Spreader


Tighten nuts (A) until spring (B) is the same length as gauge.
ANuts BSpring
UN13JUN01

OUO6075,000190D 1928JUN013/3

135-4

101801

PN=407

H68716

Service - Grain Tank and Unloading


Adjusting Grain Tank Cross Auger Drive
Loosen jam nut (A). Tighten nut (B) until washer (C) aligns with the end of gauge (D). Tighten jam nut.
AJam Nut BNut CWasher DGauge
UN10NOV99

OUO6075,0000116 1929NOV001/1

Replacing Unloading Auger Drive Belt


CAUTION: Set parking brake, shut off engine and remove key. Be certain drive is disengaged. Remove four bolts (A) and trap (B). Loosen belt trap (C). Remove both belts (D).
UN03APR01

IMPORTANT: Always replace both belts as a matched set to insure equal wear. Adjust belt trap (C). Install belt trap (B). If the unloading auger drive will not shut off (disengage) as the new belts stretch (See Unloading Auger Drive Cylinder Adjustment).
ABolts BTrap CBelt Trap DBelts

OUO6075,000190E 1928JUN011/1

140-1

101801

PN=408

H61369

UN05OCT99

H67164

H61784

Service - Grain Tank and Unloading

Aligning Unloading Auger Drive

ANuts BBolts

CNuts DArm

EArm

FAdjustment Nuts

Continued on next page

OUO1035,000030B 1920SEP001/2
101801

140-2

PN=409

H59720

UN25AUG99

H59721

UN25AUG99

Service - Grain Tank and Unloading


Check for 657 mm (25-7/8 in.) dimension from bottom of arm (E) to side sheet. Adjust with nuts (F). Adjust bolt out (toward sheave) or in (away from sheave) to move arm to equal spacing. This adjustment is a twisting action. Tighten nuts (A).

CAUTION: Set parking brake, shut off engine and remove key. Loosen nuts (A) shown in top view. Loosen nuts (C) and adjust two bolts (B) until top of arm (D) is 657 mm (25-7/8 in.) from side sheet. Tighten nuts (C).

OUO1035,000030B 1920SEP002/2

Adjusting Unloading Auger Drive Cylinder


If the unloading auger drive will not shut off (disengage), or if the belts jump off as they stretch from use, the cylinder rod stop may need adjustment. A belt that has stretched can cause the drive not to shut off. The belt rotating around the belt trap can fold over and make contact with the upper sheave. To adjust the stop: CAUTION: Set parking brake, shut off engine and remove key. Mark present stop position on rod with tape (A). Loosen nut (B) to relieve spring tension. Loosen bolts (C) and slide stop (D) toward cylinder 13 mm (1/2 in.). Tighten bolts (C). Tighten nut (B) to its original position.
UN05OCT99

ATape BNut CBolts DStop

NOTE: When installing new belts, adjust stop to its original position (stop positioned against barrel of cylinder with rod fully retracted).

OUO6035,0000085 1909NOV001/1

140-3

101801

PN=410

H61370

Service - Grain Tank and Unloading

Replacing Unloading Auger Drive Cylinder


This cylinder is not repairable. However a little oil "weeping" from breather (A) is normal and cylinder replacement may not be required.
ABreather
UN05OCT99

OUO6035,0000086 1909NOV001/1

Vertical Adjustment of Auger Support Stud


NOTE: Periodically check to be sure that the auger fully slides into the stud when the auger is fully retracted. Readjust as needed.
UN31JAN01

Loosen nuts (A) to adjust position of stud plate (B). Stud (C) should be vertically centered in hole in auger. Tighten nuts.
AHardware BPlate CStud

OUO6075,000153B 1922FEB011/1

Adjust Swing Cylinder Eyebolt


1. With hydraulic cylinder fully retracted, check gap between plate (A) and stop (B). The gap should be 1216 mm (1/25/8 in).
Specification Plate to StopGap .................................................................. 1216 mm (1/25/8 in)
UN21MAY99

APlate BStop

Continued on next page

OUO6075,000153A 1922FEB011/2
101801

140-4

PN=411

H54581

H66020

H61371

Service - Grain Tank and Unloading


2. If gap is incorrect adjust cylinder rod end (A). Loosen jam nut (B) and set screw (C). Screw cylinder rod in or out to obtain correct gap. 3. Tighten jam nut and set screw.
ACylinder Rod End BJam Nut CSet Screw
UN30JAN01

OUO6075,000153A 1922FEB012/2

140-5

101801

PN=412

H66021

Service - Electrical System


Specifications, Electrical System
Number of alternators
Output of alternator
Number of batteries
Battery voltage
Battery capacity

1
120 Amp.
2
12 V
88 AH

OUO6075,00013A7 1931JAN011/1

Batteries
The combine is equipped with two batteries, each of 12 V (88 AH). They are connected in parallel.
UN04APR95

OUO6075,00013A8 1931JAN011/1

Dangers When Handling Batteries


CAUTION: Any plastic bag or material must be removed from batteries to prevent a build-up of explosive gases. IMPORTANT: Always keep batteries clean and free from chaff. Keep all sparks or open flames away from batteries as gas from electrolyte is highly flammable. When servicing the electrical system or engine, always disconnect battery ground cables. If a battery needs a quick recharge while still installed on combine, always disconnect battery ground cable and remove battery cell filler caps before connecting the charger. This will prevent damage to the electrical system. When removing batteries, always disconnect the ground cables first and then the positive cables.
UN04APR95

ZX,OMCTS 012490 1901SEP981/1

145-1

101801

PN=413

ZX001596

ZX001595

Service - Electrical System

Battery Service
IMPORTANT: If combine is not in operation for extended periods, remove batteries and store in a cool, dry room where they will not freeze. Charge batteries at least every three months to avoid damage to cell plates. Wash batteries once a week. Remove any terminal corrosion with a brush. Coat battery terminals and cable clamps with petroleum jelly. Make sure that filler cap vent holes are not plugged.

ZX,OMCTS 012491 1901SEP981/1

Checking Electrolyte Level


CAUTION: If distilled water is added in freezing weather, run engine approximately. 30 minutes to assure thorough mixing of water and electrolyte. Check electrolyte level every 250 hours of operation. Electrolyte level should be up to the mark. If electrolyte level is low, add distilled water.

ZX,OMCTS 012492 1901SEP981/1

145-2

101801

PN=414

ZX001597

UN27MAR95

Service - Electrical System

Checking Specific Gravity


Check the specific gravity of the electrolyte using an accurate hydrometer. A fully charged battery should have a specific gravity reading of 1.28. Recharge battery if reading drops below 1.20.

NOTE: A full battery charge in tropical areas is 1.23.

ZX,OMCTS 012493 1901SEP981/1

Battery Switch
Allows the electrical system to be turned on or off.
ABattery Switch
UN26APR01

Battery Switch Shown (8.1 Liter Engine)

OUO6075,0001781 1931MAY011/1

145-3

101801

PN=415

H67695

ZX001598

UN03APR95

Service - Electrical System

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 must connect positive (+) post of booster battery to positive (+) post of combine battery. Second jumper cable must first be connected to negative (-) post of booster battery and then to a good ground on combine, away from combine batteries.

AG,OUZXMAY,404 1901DEC991/1

Installing Batteries and Connecting to Correct Poles


IMPORTANT: Make sure batteries are connected to the correct poles. The positive cable (from starter motor) to the positive (+) poles, the negative cable (from ground) to the negative () poles. Reversed polarity will result in permanent damage to the electrical system.

ZX,OMCTS 012495 1901SEP981/1

145-4

101801

PN=416

ZX001599

UN04APR95

Service - Electrical System

Welding on Machine
IMPORTANT: Welding on machine can cause damage to the Engine Control Unit (ECU). Always proceed as follows prior to welding on machine. 1. Remove the ground connection of ECU from machine frame. 2. Disconnect the connector from the ECU. 3. Connect the welder ground close to the welding point and be sure ECU or other electronic components are not in the ground path.

OUZXMAG,00007CE 1909SEP001/1

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.
ARelay

Each relay is marked by function. All relays are interchangeable.

OUO6075,000190F 1928JUN011/1

145-5

101801

PN=417

H67395

UN06APR01

Service - Electrical System

Power Distribution Board Relay Identification

K1Threshing Clearance Increase K2Threshing Clearance Decrease K3Vane Angle Adjust Left K4Vane Angle Adjust Right

K5Fan Speed Increase K6Fan Speed Decrease K7Auger Fold K8Auger Unfold K15Beacon Lamps

K16Right Turn Lamps K17Driving Lamps K18Left Turn Lamps K19Stubble Lamps K204 Field/Road Lamps

K212 Field Lamps K22Start Interlock K23Delayed Power CC6 K24Transmission Lockout K25Rear Lamps

OUO6075,0001910 1928JUN011/1

145-6

H68924

UN03JUL01

101801

PN=418

Service - Electrical System

Engine Compartment Relay Panel Fuse Identification

F1Left Control Unit Power F2Control Circuit Power F3Light Power 3 F4Light Power 4 F5Light Power 2 F6Service Accessory Power F7Press. Fan Power F8Motor Power F9Light Power 5 F10Recirculation Fan Power F11Fan Speed Adjust Power

F12Conv. Outlet Switched Power F13Unused F14Unused F15Unused F16Service Lamp Power (Optional Work Lights) F17Electronic Power F18Light Power 1 F19Conv. Outlet Unswitched Power

F20Unswitched Electronic Power F21Ignition Switch - Batt. Power F22Service Light Power (Cleaning Shoe Lights, Engine Platform Lights) F23Unused F24VP44 Rotary Pump Power (9540 Combine Only)

F25Engine Control Unit Power F26Unused F27Unused F28Header Control Unit Power F40Spare 30 Amp F41Spare 20 Amp

OUO6075,0001911 1928JUN011/1

145-7

H67408
101801

PN=419

UN11APR01

Service - Electrical System

Engine Compartment Relay Panel Identification

K1Left Control Unit Power K2Control Circuit Power K3Press. Fan Power K4Motor Power K5Fan Speed Adjust Power

K6Recirculation Fan Power K7Unused K8Conv. Outlet Switched Power K9Electronic Power

K10Service Lamp Power (Optional Work Lights) K11Header Control Unit Power K12VP44 Rotary Pump Power (9540 Combine Only)

K13Engine Control Unit Power

OUO6075,0001915 1928JUN011/1

145-8

H67473
101801

PN=420

UN11APR01

Service - Electrical System

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 avoid possible injury: 1. 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 bulb by its base. Avoid touching the glass. 4. Do not drop or scratch the bulb. Keep moisture away. 5. Place used bulb in the new bulbs carton and dispose of properly. Keep out of reach of children.
AHalogen Bulb

OUO1035,000031C 1920SEP001/1

Replacing Bulbs
If all of the lights fail in a particular system at the same time, check for a failed fuse or relay. If a single light fails, bulb may be burned out. If problem is other than fuse, relay or bulb, see your John Deere dealer.

HX,AG,SF7162 1923AUG971/1

145-9

101801

PN=421

H59774

UN30AUG99

TS266

UN23AUG88

Service - Electrical System

Cab Head Light Bulb Replacement and Adjustment


CAUTION: Raise feeder house all the way up and lower safety stop before standing on feeder house to replace or adjust these bulbs. Read SAFETY WHEN REPLACING HALOGEN BULBS.

NOTE: Center two head lamps are infrared. All others are halogen lamps.
Remove three screws (A) evenly and remove headlamp (B). Disconnect wiring (C). Clean dirt from headlamp. Push in and twist retainer ring (D) counterclockwise. Bulb pulls straight out. When installing headlamp, adjust as follows: IMPORTANT: Over tightening the screws until they bottom out can break the headlamp. Start with the two end screws first, then the bottom screw last. Adjust the screws until all three tabs are flush with the panel.
AScrews BHeadlamp CWiring DRetainer Ring

HX,AG,SF7164 1904MAR991/1

145-10

101801

PN=422

H39475

UN30JUN00

Service - Electrical System

Replacing Stubble Light (Optional) Bulb


Remove screw (A) and cover (B). Disconnect wiring lead (C). Clean dirt from light Push in and twist retainer ring counterclockwise. Bulb (D) pulls straight out. Install new bulb in reverse order.
AScrew BCover CWiring Lead DRetainer Ring
UN09MAR99

HX,AG,SF7165 1904MAR991/1

Replacing Field Light Bulb


CAUTION: Shut off engine, set parking brake and remove key.
UN24JAN01

Remove screws and cover. Disconnect wiring lead. Clean dirt from light. Push in and twist retainer ring counterclockwise. Bulb pulls straight out. Install new bulb in reverse order.

OUO6075,00013AA 1931JAN011/1

145-11

101801

PN=423

H65913

UN24JAN01

H65912

H54495

UN09MAR99

H54330

Service - Electrical System

Replacing Side Finder Light Bulb


Disconnect wiring lead (A) and clean dirt from light. Push in and twist retainer ring (B) counterclockwise. Bulb pulls straight out.
UN05SEP97

Install new bulb in reverse order.


AWiring Lead BRetainer Ring

OUO1035,0000321 1920SEP001/1

Replacing Grain Tank Light Bulb


NOTE: Grain tank light shown removed from combine for photographic clarity.
Disconnect connector (A) from wiring harness. Carefully pry out light from rubber housing (B). Disconnect wiring leads (C) from bulb. Install new bulb in reverse order.
AConnector BHousing CWiring Leads
UN10DEC98

OUO1035,0000322 1920SEP001/1

145-12

101801

PN=424

H51670

H49824

Service - Electrical System

Replacing Cleaning Shoe Light Bulb


Disconnect wiring (A) and clean dirt from light. Push in and twist ring retainer (B) counterclockwise. Bulb pulls straight out. Install new bulb in reverse order.
AWiring BRing Retainer
UN03APR01

OUO6075,00015D5 1903APR011/1

Replacing Warning Light Bulb


Remove screws (A) from lens covers. Remove bulb by pushing in and turning counterclockwise. Install new bulb in reverse order.
AScrews
UN01FEB01

OUO6075,0001784 1931MAY011/1

145-13

101801

PN=425

H68388

UN04JUN01

H66115

H67165

Service - Electrical System

Replacing Turn Signal Indicator Light Bulb


1. Tilt steering column toward drivers seat. 2. Remove four screws and remove steering column cover (A). 3. Pull out bulb socket (B) (bulb pulls straight out).
ASteering Column Cover BBulb Socket
UN13APR92

AG,OUO1035,1591 1924JAN001/1

Replacing Dome and Console Light Bulb


Remove dome or console lens cover by pressing sides of cover. Replace dome (A) or console (B) bulb. Install lens covers by snapping in place.
ADome Light BConsole Light
UN11DEC98

HX,SERVES,V 1922JUL991/1

145-14

101801

PN=426

H51673

H44231

Service - Electrical System

Replacing Warning Display Panel Light Bulb


Remove six screws (A) attaching display panel and lower panel. Remove screws (B), (C) and circuit board. Remove defective bulb by pulling straight out. Install new bulb in reverse order.
AScrews BScrews CScrews
UN02FEB01

OUO6075,00013C1 1902FEB011/1

Observe Electrical Precautions


CAUTION: Keep all sparks and flames away from batteries as gas given off by electrolyte is explosive. To avoid sparks, connect ground cable last and disconnect it first. To avoid shocks and burns, disconnect battery ground cable before servicing any part of electrical system or when removing batteries.

HX,AG,SF7172 1905NOV901/1

145-15

101801

PN=427

H57295

UN18MAY99

H40946

UN12JUL89

H51562

UN02MAR99

H66146

Service - Electrical System

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 running. 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 (if possible). Why: Electrical loads in the system 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 machine is running. Why: This can cause computer system errors from interrupting a computer program while it is 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 harnesses that are involved in the ground path. Welding can also cause electrical voltage spikes that can damage electronic components.

AG,OUO1035,2118 1901MAY001/1

Starter
If starter fails to operate or operates sluggishly, the cause may not be in starter but one of the following: Loose, dirty, broken or corroded cables and wires. Low battery output. Run down batteries. Crankcase oil of wrong viscosity.

Remove access panel in grain tank to get at starter. If these checks do not correct the problem, see your John Deere dealer.

HX,AG,SF7179 1923AUG971/1

145-16

101801

PN=428

H49047

UN25JUL97

Service - Electrical System

Alternator and Voltage Regulator


Always disconnect battery ground cable before working on alternator (A) or regulator. The combine is equipped with a 120 amp alternator. Never attempt to polarize alternator or regulator. Never ground a terminal or connect a jumper wire to any alternator terminals. Never connect or disconnect alternator wires with batteries connected or alternator operating.
AAlternator

OUO6075,00015D6 1903APR011/1

Header Drive Electromagnetic Clutch


CAUTION: Shut off engine, set park brake and remove key.
UN06JUN01

If the clutch (A) will not work, check the following: Check and tighten all electrical connections between clutch and batteries. Examine wiring and repair as needed. Clean any grease from drive plate friction surface. Check drive plate for free movement. Voltage across hot terminals must be 11 volts minimum with engine off and electric clutch on. If voltage light on the display panel is off, the electrical system has a minimum of 11 volts. If these checks do not correct the problem, see your John Deere dealer.

AHeader Clutch

OUO6075,0001917 1928JUN011/1

145-17

101801

PN=429

H68538

H67126

UN02APR01

Service - Electrical System

Antenna Mounting
To install a radio or a CB radio see your John Deere dealer. A additional antenna mount (A) is located in the center of the cab roof. A additional antenna cable (B) is located on the right-hand side of the cab under the armrest console.
AAdditional Antenna Mount BAdditional Antenna Cable

HX,AG,SF7182 1901SEP981/1

145-18

101801

PN=430

H65641

UN20DEC00

H64104

UN01JUN00

Service - Hydraulic System


Hydraulic System (General Information)
The combine hydraulic system is an open center system. In an open center system the pump runs continuously, even when system components are not activated (system is in neutral). When the system is in neutral, oil flows through the system and back to the reservoir - the "open center" feature. There are two reservoirs in the hydraulic system; the hydraulic/hydrostatic reservoir and the steering/engine gearcase reservoir. The hydraulic/hydrostatic reservoir supplies oil for the hydraulic and hydrostatic systems. The steering/engine gearcase reservoir supplies oil for the steering, separator engage wet clutch, gearcase lubrication and unloading auger engage systems. There are two oil coolers; one each for the reservoirs. Oil cooler bypass valves provide quick warm-up of the oil in cold weather. There are three oil filters providing filtration for the hydrostatic system, the steering/engine gearcase system and the combined return oil from the hydraulic and hydrostatic systems. There are three pumps supplying oil to the steering/engine gearcase system, hydraulic system and the hydrostatic system. The hydrostatic system uses its own charge pump to supply oil to the hydrostatic ground speed drive unit. CAUTION: It is normal for the system to allow a raised feeder house (with or without a header) to slowly lower to the ground after a long period of time. Always lower the safety stop when the combine is unattended. If the feeder house should lower itself to the ground in less than 12 hours (approximate), see your John Deere dealer. IMPORTANT: The components in this system are built to very close tolerances and have been adjusted at the factory. Do not attempt to service these components except to maintain proper oil level and to change oil and filter. See your John Deere dealer for all other service.

OUO6075,0001989 1926JUL011/1

150-1

101801

PN=431

Service - Hydraulic System

Hydraulic System Cleanliness


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. 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 may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Cleanliness If the hydraulic system should be disconnected for service, protect the ends of hoses, tubing and ports of components from contamination with clean, lint-free towels or clean plastic bags. Before installing any replacement hose, flush the inside with unused diesel fuel or unused commercial petroleum cleaning solvent for ten seconds minimum. Do not use water, water soluble cleaners or compressed air.

HX,AG,SF7185 1914MAR971/1

150-2

101801

PN=432

X9811

UN23AUG88

Service - Hydraulic System

Accumulator (General Information)


IMPORTANT: Every time the header is changed or the skid plates are installed/removed, have your John Deere dealer check and if necessary re-adjust the pressure charge of the lift system accumulator. The accumulator system (A) is connected to the header lift system between the lift cylinders and solenoid control valve. It suspends the header over uneven ground by compressing nitrogen gas with a piston in the accumulator tank.
AAccumulator System

The accumulator has a volume of 0.7 L (0.19 U.S. gal). The accumulator is maintenance-free and cannot be repaired if damaged.

OUO6075,0001918 1928JUN011/1

Valve for Raising/Lowering Header (Proportional Valve)


Oil at a flow of (52 L/min; 13.7 gpm) reaches valve (A) from the first pump. The pressure relief valve is set to 21000 kPa (210 bar; 3045 psi). There are 3 internal valves: Neutral flow valve Raise (solenoid) valve Lower (solenoid) valve When raising, the neutral flow valve automatically closes. The entire oil flow returns via the filter in neutral flow or when the pressure relief valve is triggered. When lowering, the entire return flow discharges from the cylinders and goes directly to the tank.
UN05JUN01

AValve

OUO6075,0001919 1928JUN011/1

150-3

101801

PN=433

H68530

H68530

UN05JUN01

Service - Ground Speed Drive


Adjusting Gearshift Linkage
If the gearshift lever is hard to shift, it does not necessarily mean that the cable needs adjustment. Hard shifting can be caused by: A damaged, dirty, rusty or pinched shift cable. For these problems, inspect, clean, adjust or replace the cable. Internal transmission problems. If you suspect a transmission problem, see your John Deere dealer. To adjust the linkage, shift transmission into second gear. The gearshift lever should be leaning slightly forward when in second gear. From under cab, loosen nut (A) and adjust balljoint (B) to meet specification (C).
Specification BalljointDistance......................................................................... 237 mm (9-5/16 in.)
UN12JUN01 UN12JUN01

Do not adjust clamp (D). At the transmission, shift arm (E) should be straight down as shown. Loosen nut (F) and adjust balljoint (G) until the stud on the balljoint aligns with the hole in shift arm (E). Check for specification at (H).
Specification BalljointDistance......................................................................... 237 mm (9-5/16 in.)

Shield Removed for Clarity


ANut BBalljoint CMeasurement of 237 mm (9-5/16 in.) DClamp EShift Arm FNut GBalljoint HMeasurement of 237 mm (9-5/16 in.) IClamp

Do not adjust clamp (I).

OUO6075,000191B 1928JUN011/1

Brake Fluid
IMPORTANT: When removing reservoir cap, keep contaminants from entering the reservoir. Fluid should be 6 mm (1/4 in.) from top. Fill reservoir with SAE J1703d, DOT-3 or DOT-4 hydraulic brake fluid.

OUO6075,000175C 1930MAY011/1

155-1

101801

PN=434

H68704

H68534

Service - Ground Speed Drive

Brake System
If you experience soft or spongy brakes, a loss of braking power or the parking brake will not hold, see your John Deere dealer.

OUO6075,0001511 1921FEB011/1

Cleaning Hydrostatic Oil Cooler


CAUTION: Shut off engine, set parking brake and remove key.
UN02JUL01

Release latch (A) and pull out rotary screen door (B). Pull out oil cooler and condenser to clean. Clean out lower vacuum duct after cleaning. Keep fins on cooler straight.
ALatch BRotary Screen Door

OUO6075,000191C 1928JUN011/1

155-2

101801

PN=435

H68535

Service - Air Conditioning and Heater


Observe Air Conditioning Precautions
CAUTION: Refrigerant (R134A) under pressure. Improper servicing may cause refrigerant to penetrate eyes and skin or cause burns. Special equipment and procedures are required to service air conditioning system. (See your John Deere dealer.)
UN20JUL92

HX,AG,SF7215 1911SEP921/1

CLIMATRAK Air Conditioning System (General Information)


Air is drawn into the cab through holes (A). This air flows down air duct (B) and into the pressurizer fan (C). The air is then pushed through the pre-cleaner (D) where the majority of dirt and a small amount of air is discharged out through the cab floor. Be certain this opening is open. This cleaned air then passes through fresh air filter (E) into the evaporator compartment. The air is now mixed with air from inside the cab, being drawn into the evaporator compartment through the recirculating filter (F) . It then passes through the evaporator and heater core. Treated air (heated or cooled) is now drawn into the recirculator blower (G) and discharged into the cab through ducts. (H). CLIMATRAK Sensors Monitor Inlet air temp. Air temp coming out of the ducts. Evaporator core temp to prevent icing. Solar loads. Cab air temp. Sensor is located behind the operator, and is critical for the system to recognize the temperature the operator is experiencing. Covering this sensor causes the system to respond slower to changes in heat loads. Use provided coat hook to hang your coat.
UN31AUG99

AHoles BAir Duct CPressurizer Fan DPre-Cleaner EAir Filter FRecirculating Filter GRecirculator Blower HDuct

OUO6075,000175D 1930MAY011/1

160-1

101801

PN=436

H59794

H44933

Service - Air Conditioning and Heater

Cleaning Fresh Air Filter and Recirculating Filter


Clean filter by one of the following methods: Tap gently on flat surface, dirty side down. Do not tap on a tire. Blow compressed air through filter in opposite direction of arrows on filter. Soak 15 minutes in warm (not hot) water with R36757 John Deere Dry Filter Element Cleaner or its equal (non-sudsing detergent). Rinse until clean with water from hose. Do not use a high pressure washer. Shake extra water from filter and allow element to dry. Do not use compressed air to dry filter. It may rupture it.

HX,AG,SF7218 1924MAY991/1

Removing Evaporator Filter


Clean this filter only if other service does not provide enough cooling. The evaporator filter can be inspected from outside the cab after removing the fresh air filter. If it looks clean, do not remove and clean it. Remove five screws in seat console. Remove six screws and evaporator cover. Remove two nuts and cap screws (A). Remove controller (B). Remove evaporator filter (C). Clean as you would the other filters.
ACap Screws BController CEvaporator Filter
UN10MAR99 UN10MAR99

HX,AG,SF7221 1909OCT911/1

160-2

101801

PN=437

H54344

H54341

Service - Air Conditioning and Heater

Cleaning Cab Roof Inlet Panel


Clean this panel only when it looks plugged. Remove six screws (A) and remove panel (B). Air is brought in through the left-hand side panel only. The right-hand side panel does not provide cab air. Clean with compressed air or water.
AScrews BPanel

HX,AG,SF7222 1920MAR901/1

Cleaning Condenser
CAUTION: Turn off engine, remove key and set parking brake.
UN02JUL01

Release latch (A) and open rotary screen door (B).


ALatch BRotary Screen Door

OUO6075,000191D 1928JUN011/2

Pull out condenser (A) and oil cooler to clean. Clean oil cooler, condenser and radiator. Clean out lower vacuum duct (B) and duct (C). IMPORTANT: When using high pressure air or water, be careful of fin damage to coolers. Use a fin comb to straighten bent fins. Bent fins will decrease cooler performance. Keep fins on condenser straight. After cleaning, close and latch rotary screen door.
ACondenser BVacuum Duct CDuct
UN03APR01

OUO6075,000191D 1928JUN012/2

160-3

101801

PN=438

H67162

H68535

H54345

UN10MAR99

Service - Air Conditioning and Heater

Engine Accessory Drive Belt Routing (6.8 Liter Engine)


AAlternator BRotary Screen Drive Sheave CRotary Screen/Alternator Sheave DTensioner EAir Conditioning Compressor FFan Belt GSpring Loaded Tensioner HRotary Screen Driven Sheave IRotary Screen Drive Belt JEngine Crankshaft Sheave KSpring Loaded Tensioner LAlternator Belt MWater Pump Sheave NFan Drive Sheave OTensioner

C
E
D

G
N
UN01AUG01

I
J

OUO6075,000199A 1901AUG011/1

Engine Accessory Drive Belt Routing (8.1 Liter Engine)


ASpring Loaded Idler BAlternator CAlternator Belt DWater Pump Sheave EFan Belt FAir Conditioning Compressor GTension Idler HRotary Screen Driven Sheave IRotary Screen Drive Belt JRotary Screen Drive Sheave KEngine Crank Shaft Sheave LSpring Loaded Idler MFan Drive Sheave

B
A
D

E
F

G
L

M
UN10APR01
101801

J
K

OUO6075,00016CE 1916MAY011/1

160-4

PN=439

H67319

H69505

Service - Air Conditioning and Heater

Removing Compressor Drive Belt


CAUTION: Shut off engine, remove key and set parking brake.
UN05APR01

1. Remove bolts (A) and fan (B).


ABolts (6 used) BFan

Engine Fan Bolts

OUO6075,00016D6 1916MAY011/6

2. To remove alternator belt, insert 13 mm (1/2 in.) drive breaker bar (A) into square hole in idler to release tension on belt. 3. Remove belt (B) from alternator.
A13 mm (1/2 in.) Breaker Bar BBelt
UN05APR01

OUO6075,00016D6 1916MAY012/6

4. Remove nut (A) and loosen nut (B) to relieve spring tensioning. 5. Remove spring pin (C) and washer from tensioning rod. 6. Remove tensioning rod from hole to relieve tension. 7. Remove belt (D).
ANut BNut CSpring Pin DBelt
UN05APR01

Continued on next page

OUO6075,00016D6 1916MAY013/6
101801

160-5

PN=440

H67321

H67317

H67316

Service - Air Conditioning and Heater


8. To remove engine accessory drive belt, insert a 13 mm (1/2 in.) drive breaker bar (A) into the square hole in idler to release tension on the belt. 9. Remove belt (B). 10. Install engine accessory drive belt in reverse order.
A13 mm (1/2 in.) Breaker Bar BBelt
UN05APR01

OUO6075,00016D6 1916MAY014/6

11. Install rotary screen drive belt (D). 12. Install tensioning rod, washer and spring pin (C). 13. Install and tighten nut (B) until gauge is at the end of spring. 14. Install and tighten nut (A).
ANut BNut CSpring Pin DBelt
UN05APR01

OUO6075,00016D6 1916MAY015/6

15. Install fan (B) and tighten fan bolts (A) to specification.
Specification Fan BoltsTorque ......................................................................... 62 Nm (45 lb-ft)
UN05APR01

ABolts (6 used) BFan

Engine Fan Bolts

OUO6075,00016D6 1916MAY016/6

160-6

101801

PN=441

H67316

H67321

H67322

Service - Air Conditioning and Heater

High Pressure Switch


A high pressure condition can result from insufficient air flow across the condenser. When this happens, switch (A) (next to radiator) shuts off the compressor. Shut off engine, remove key and set parking brake. Clean condenser and filters. Check for a broken fan belt. Start engine and turn on air conditioning. If switch shuts off compressor again, see your John Deere dealer.
UN10MAR99

AHigh Pressure Switch

HX,AG,SF7227 1919MAY991/1

Low Pressure Switch


Low pressure (A) (located under instructional seat) protects the compressor if refrigerant is lost. The switch can also activate if there is insufficient air flow across the evaporator. It can also cause the compressor to cycle on cool days or if there is a slow leak in the system. If the compressor cycles excessively, or if there is no cooling, see your John Deere dealer.
ALow Pressure Switch

OUO6075,000011F 1901DEC001/1

160-7

101801

PN=442

H54348

UN10MAR99

H54347

Trouble Shooting
Feeder House
Symptom Problem Solution

Uneven or bunched feeding of crop to cylinder.

Header auger too high.

Adjust auger down and back. See header operators manual. Lower reel and set fore-and aft position as close as possible to cutterbar and auger. See platform operators manual. Adjust feeder drum so conveyor slat clears bottom with correct clearance. Adjust conveyor chain to correct tension. Spring-loaded idler must be free and tight against belt. Adjust auger back to stripper. See header operators manual. Place chain on correct sprocket.

Buildup of grain on cutterbar.

Front of feeder conveyor chain adjusted too high. Feeder conveyor chain too tight and holds drum up. Header drive belt slipping.

Auger too far ahead of stripper.

Feeder conveyor drive chain not on correct sprocket. Feeder conveyor slats bowed up. Dirt and sap buildup on feeder house bottom. Too great a distance between platform auger and feeder house front drum. Header or Reel Will Not Lift Correctly Air in hydraulic system.

Straighten or replace bent slats. Clean bottom.

Add links to feeder house chain.

Tighten clamps on leaking lines or hoses. Bleed reel lift system. See Platform operators manual.

HX,AG,SF7232 1915APR981/1

165-1

101801

PN=443

Trouble Shooting

Separator
Symptom Problem Solution

Cylinder Not Getting Full Speed Range Slugging or Overloading of Cylinder.

Loose belts.

Adjust belts.

Engine not up to correct speed.

See your John Deere dealer.

Variable speed cylinder belt slipping at slow speed. Hydraulic problem. Concave-to-cylinder spacing too close or too wide. Cylinder speed too slow for crop. Too much material entering cylinder. Backfeeding of Cylinder. Engine not up to correct speed. Separator curtains slowing crop too much. Second concave in upper position.

Adjust sheave gap.

See your John Deere dealer. Adjust concave-to-cylinder spacing.

Increase cylinder speed. Reduce ground speed. See your John Deere dealer. Remove front curtain.

Lower second concave.

Continued on next page

HX,AG,SF7233 1915APR981/4

165-2

101801

PN=444

Trouble Shooting
Symptom Problem

Solution

Grain Not Threshed

Crop not ready to thresh.

Test moisture of crop before combining. Increase cylinder speed enough to do a good job of threshing but do not increase speed to the point where grain cracks. Level concave. See your John Deere dealer. Close cylinder-to-concave spacing until tight bar ticks to increase threshing action. Install concave cover plates to keep unthreshed heads from passing through grate. Check feeder conveyor chain tension and float in feeder house. Increase ground speed.

Cylinder speed too slow.

Concave not level.

Cylinder to concave spacing too wide.

Unthreshed heads passing through concave.

Uneven feeding to cylinder.

Not enough material entering combine for proper threshing action. Too Much Cracked Grain In Tank. Cylinder speed too fast for crop.

Decrease cylinder speed just enough to stop grain cracking, but still do a good threshing job, and/or open concave slightly. Open cylinder-to-concave spacing just enough to stop cracking. Open sieve slightly to reduce tailings.

Cylinder-to-concave spacing too close. Too much clean grain in tailings, causing grain to crack when rethreshed.

Reduce fan speed. Not enough straw entering combine. Dented auger housings or bent auger shafts cracking grain between flights and housings. Increase ground speed. Remove dents from auger housings and/or straighten bent auger shafts.

Continued on next page

HX,AG,SF7233 1915APR982/4
101801

165-3

PN=445

Trouble Shooting
Symptom Problem

Solution

Grain Loss Over Straw Walkers.

Damaged or missing straw walker curtain. Straw walker overloaded due to incomplete threshing or late threshing at concave. Straw walker openings plugged so threshed grain cannot drop through to walker return pan. Straw walkers overloaded so grain cannot get through material to walker return pan.

Install new curtain.

Reduce cylinder to concave spacing and/or increase cylinder speed to increase threshing action. Clean out openings in straw walkers.

Reduce ground speed. Check to be both curtains are in place.

Raise platform to cut less material. Second concave in low position. Move second concave to high position. Cylinder-to-concave setting too close and/or cylinder speed too fast. Increase spacing. Extend walker pans. Reduce fan speed and/or increase chaffer opening. Remove front curtain.

Material over threshed and pulverized.

Straw walker pans not extended. Almost No Chaff in Tailings. Grain Tank Very Clean. Material Lodging On Straw Walker and Not Being Evenly Discharged From Rear of Combine Fan speed is too high and/or chaffer not open far enough. Material catching on straw walker curtain and building up on front of walkers.

Material not flowing evenly to walkers. Some Chaff in Tailings. Grain Tank Clean. Heavy Chaff in Tailings. Grain Tank MAY Range From Good To Dirty. Sieve is closed too tight.

See "SLUGGING OR OVERLOADING OF CYLINDER". Open sieve.

Sieve is closed too tight and fan is too slow.

Open sieve and increase fan speed.

Continued on next page

HX,AG,SF7233 1915APR983/4
101801

165-4

PN=446

Trouble Shooting
Symptom Problem

Solution

Too Much Trash (Ground Up Weeds) in Tailings.

Chaffer and extension too far open for weedy conditions. Cylinder too fast or concave too tight.

Close chaffer and extension.

Reduce cylinder speed and/or open cylinder-to-concave spacing. Close sieve.

Dirty Grain Tank (Unthreshed Heads).

Sieve too far open.

Pre-cleaner open. Cylinder not threshing enough.

Close pre-cleaner. Increase cylinder speed and/or close cylinder-to-concave spacing. Increase fan speed. Adjust or close pre-cleaner.

Dirty Grain Tank (Mostly Chaff).

Fan speed too slow. Pre-cleaner too far open in corn or pre-cleaner not closed in grain crops.

Loss of Grain Over Cleaning Shoe (Grain Tank is Clean).

Chaffer closed.

Open chaffer.

Pre-cleaner closed (corn only). Fan speed incorrect.

Open pre-cleaner. Adjust fan speed. Check tailings, losses and grain tank. Reduce fan speed.

High Grain Losses (Occurs At Low Feedrates or High Feedrates).

Fan speed too fast.

Chaffer not open far enough. Pre-cleaner not open far enough. High Grain Losses (Occurs at High Feedrates Only). Unloading Auger Will Not Shut Off. Cleaning Shoe Sensors Plugging Up with Trash. Fan speed too low.

Open chaffer. Open pre-cleaner. Increase fan speed.

Cylinder rod stop out of adjustment.

Adjust stop.

Trash is getting caught between plastic fingers and sensor.

Remove fingers over the sensor.

HX,AG,SF7233 1915APR984/4

165-5

101801

PN=447

Trouble Shooting

Hydrostatic Ground Drive


Symptom Problem Solution

Speed Range Selector Will Not Go In Reverse. Linkages Binding.

Bent or broken parts in control linkage. Frozen or worn ball joints on control cable. Bell crank or pivots binding. Control cable kinked or frozen.

Repair or replace as required.

Lubricate or replace.

Lubricate or replace. Replace if needed. Blow air through core and clean. See your John Deere dealer. Check for worn belt. Change filter. Shift to lower gear. See your John Deere dealer. See your John Deere dealer. Tighten connections or replace damaged lines, hoses or O-rings. See your John Deere dealer.

System Overheats.

Oil cooler or radiator plugged. Lack of charge oil flow. Engine fan belt slipping or broken. Plugged oil filter. Exceeding relief valve pressure. Relief valve stuck closed. By-pass valve fails to close.

High Oil Loss.

Loose connections or leaking hydraulic lines, hoses or O-rings. Hydrostatic drive units leaking.

Continued on next page

HX,AG,SF7234 1915APR981/3

165-6

101801

PN=448

Trouble Shooting
Symptom Problem

Solution

Combine Will Not Move Forward or Reverse.

Transmission out of gear.

Shift transmission.

Low on oil.

Check for leaks and correct. Fill reservoir. Tighten connections. Tighten loose linkages or replace as needed. See your John Deere dealer.

Air leak in system. Control linkages broken or loose.

Lack of charge flow or charge pressure. Plugged filter. Exceeding maximum operating pressure setting. Drive system unable to build up pressure. Relief valve open. Transmission Hard to Shift or Will Not Shift. Speed range control lever not in neutral. Transmission shift linkage out of adjustment. Damaged, dirty, rusty or pinched shift cable. Internal transmission problem.

Change filter. Shift to lower gear.

See your John Deere dealer.

See your John Deere dealer. Move control lever to neutral.

Adjust transmission shift linkage.

Inspect, clean, adjust or replace cable. See your John Deere dealer.

Continued on next page

HX,AG,SF7234 1915APR982/3

165-7

101801

PN=449

Trouble Shooting
Symptom Problem

Solution

Ground Travel Speed Erratic.

Low oil.

Check for leaks and correct. Fill reservoir. Tighten line connections and clamps or replace as needed. Change filter. Shift to lower gear.

Oil leak from lines.

Plugged filter. Exceeding maximum operating pressure setting. Speed control lever creeps toward neutral. System unable to keep charge pressure. Combine Will Not Stop When Speed Range Selector is in Neutral Position. Lack of Power or Lost Power. Combine Not Responding To Speed Range Selector. Control cable out of adjustment.

See your John Deere dealer.

See your John Deere dealer.

Adjust cable for neutral position.

Low on oil.

Check for leaks and correct. Fill reservoir.

Plugged filter. Lack of charge flow or charge pressure. Leaking or broken oil line or connection.

Change filter. See your John Deere dealer.

Check and repair as needed.

HX,AG,SF7234 1915APR983/3

165-8

101801

PN=450

Trouble Shooting

4-Wheel Drive (Optional)


Symptom Problem Solution

Combine Will Not Move When 4-Wheel Drive Is Engaged.

One or both rear wheels in spin-out condition.

Increase hydrostatic pump flow by moving hydrostatic control lever forward. See your John Deere dealer

Bad electrical control switch on console. Bad solenoid valve on control valve. Spool will not move in control valve. Combine Will Not Move When 4-Wheel Drive Is Disengaged. Faulty line or connection between main system and rear wheel drive control valve. Bad electrical control switch on console. Bad solenoid valve on control valve. Spool will not work in control valve. Rear Wheels Wander During Transport Speeds. Toe-in out of adjustment.

See your John Deere dealer. See your John Deere dealer. Repair or replace parts as needed.

4-Wheel Drive Will Not Disengage.

See Your John Deere dealer

See your John Deere dealer. See your John Deere dealer. Adjust toe-in.

HX,AG,SF7235 1915APR981/1

Steering
Symptom Problem Solution

Rear Wheels Wander During Transport Speeds. Steering Arms Do Not Contact Stops at Full Turns. Hard Steering.

Toe-in out of adjustment.

Adjust toe-in.

Steering cylinder out of adjustment.

Adjust cylinder.

Low oil level in engine gearcase reservoir.

Add oil.

HX,AG,SF7236 1913DEC931/1

165-9

101801

PN=451

Trouble Shooting

Brakes
Symptom Problem Solution

Spongy Brake Pedal Pressure.

Low brake fluid level. Air in the system.

Add brake fluid. See your John Deere dealer. See your John Deere dealer. See your John Deere dealer. Adjust park brake. See your John Deere dealer.

Loss of Braking Power.

Glazed linings. Worn linings.

Parking Brake Not Holding.

Park brake not adjusted properly. Glazed linings.

HX,AG,SF7237 1909OCT911/1

165-10

101801

PN=452

Trouble Shooting

Engine
Symptom Problem Solution

Engine Hard to Start Or Will Not Start.

No fuel.

Fill tank with correct fuel and bleed air from system. Change filter. Move multi-function lever to neutral. Drain, flush, fill and bleed system. Replace filter and bleed air. Use correct fuel for operating conditions. Check wiring to fuel pump. See your John Deere dealer. Clean and tighten all connections on batteries and starter relay. Drain and fill crankcase with oil of correct viscosity and quality. See your John Deere dealer. Add oil of correct viscosity. Bleed fuel system. See your John Deere dealer. See your John Deere dealer. See your John Deere dealer. Write the code on a piece of paper and call your John Deere dealer.

Clogged water filter. Switches not in correct positions. Water, dirt or air in fuel system. Clogged fuel filter. Wrong type of fuel.

Fuel pump disconnected. Dirty or faulty injectors. Too much resistance in starting circuit. Crankcase oil of too heavy viscosity.

Low compression. Engine Knocks Low oil. Air in fuel system. Injection pump out of time. Injection nozzle valve sticking. Internal engine problem. Triple Display Tachometer Displays Engine Stop Code (1) Electronic engine control is sending a diagnostic code to the tachometer.

Continued on next page

HX,AG,SF7238 1915APR981/5

165-11

101801

PN=453

Trouble Shooting
Symptom Problem

Solution

Engine Runs Irregularly or Stalls Often.

Low coolant temperature.

Run engine until warm.

Clogged water filter. Clogged fuel filter.

Change filter. Replace filter and bleed the fuel system. Clean filter vent. Drain, flush, fill and bleed system. See your John Deere dealer. See your John Deere dealer. See your John Deere dealer. Change filter. See "Engine Overheats" below. Clean air cleaner. Replace filter and bleed system. Replace filter. Clean filter vent. Engine loses horsepower with increases in altitude. Use correct type of fuel for high altitude. See your John Deere dealer. See your John Deere dealer. Check for air leaks and repair.

Clogged fuel tank filter vent. Water, dirt or air in fuel system. Dirty or faulty injectors. Injection pump out of time. Bent push rods or sticky valves. Lack of Power. Clogged water filter. Overheated engine. Intake air restriction. Clogged fuel filter. Clogged water filter. Clogged fuel tank filter vent. High altitude operation.

Dirty or faulty injectors. Injection pump out of time. Air intake leaks.

Continued on next page

HX,AG,SF7238 1915APR982/5

165-12

101801

PN=454

Trouble Shooting
Symptom Problem

Solution

Engine Overheats.

Low coolant level.

Fill radiator with coolant to the correct level. Check hoses and radiator for leaks or loose connections. Clean radiator and rotary screen.

Dirty cooling system radiator core or rotary cooling screen. Rotary cooling screen not turning.

Broken drive belt. Belt off sheaves.

Loose or broken fan belt. Cooling system limed up. Defective thermostats. Vacuum duct plugged. Fan on low speed. Low Oil Pressure. Low oil level.

Replace worn belt. Drain and flush cooling system. See your John Deere dealer. Clean duct. Increase speed. Check crankcase oil level and add oil if needed. Drain and fill crankcase with oil of correct viscosity. Clean oil cooler. Check air cleaner and clean air intake. Check for leaks in lines and around gaskets and drain plugs. Drain and fill crankcase with oil of the correct viscosity. Clean oil cooler. See your John Deere dealer. See your John Deere dealer.

Wrong type of oil.

Oil cooler plugged. Engine Uses Too Much Oil. Restricted air intake system.

Oil leaks.

Too low viscosity crankcase oil.

Oil cooler plugged. Scored piston. Internal parts worn.

Continued on next page

HX,AG,SF7238 1915APR983/5
101801

165-13

PN=455

Trouble Shooting
Symptom Problem

Solution

Engine Uses Too Much Fuel.

Clogged or dirty air cleaner. Wrong type of fuel.

Clean air cleaner. Use correct type of fuel for operating conditions. See your John Deere dealer. See your John Deere dealer. Check air cleaner for plugging. Filter element must be clean. Use correct type of fuel for operating conditions. See your John Deere dealer. Bleed fuel system. Check muffler for possible damage that might create back pressure. See your John Deere dealer. Warm engine to normal operating temperature. See your John Deere dealer. Low cetane fuel will cause misfiring. Use only fuel which has correct cetane number. See your John Deere dealer. Adjust belt or replace worn belt. Clean and tighten battery connections. See your John Deere dealer.

Dirty or faulty injectors. Engine out of time. Engine Blows Black Or Gray Exhaust Smoke. Clogged or dirty air cleaner.

Wrong type of fuel.

Dirty or defective injectors. Air in fuel system. Defective muffler.

Engine out of time. Engine Blows White Exhaust Smoke. Cold engine.

Engine out of time. Wrong type of fuel.

Defective thermostats. Batteries Will Not Charge. Loose or defective alternator belt. Loose or corroded connections.

Alternator or voltage regulator not working right.

Continued on next page

HX,AG,SF7238 1915APR984/5
101801

165-14

PN=456

Trouble Shooting
Symptom Problem

Solution

Starter Cranks Slowly or Will Not Operate.

Relay not working.

Check relay and wire connections.

Loose or corroded battery connections. Key switch worn or terminals loose. Too high viscosity crankcase oil.

Clean and tighten loose connections.

Check switch and terminals. Drain and fill crankcase with oil of correct viscosity and quality.

HX,AG,SF7238 1915APR985/5

Heater
Symptom Problem Solution

Heater Not Blowing Warm Air.

Dirty recirculating filter. No thermostat in water outlet manifold. Defective thermostat in water outlet manifold. Heater temperature control defective. Kinked heater hose. Defective heater valve.

Clean filter. See your John Deere dealer.

See your John Deere dealer.

See your John Deere dealer. Straighten or replace. Replace valve. See you John Deere dealer.

HX,AG,SF7239 1915APR981/1

165-15

101801

PN=457

Trouble Shooting

Air Conditioning
Symptom Problem Solution

Lack Of Or Insufficient Cooling

Temperature slide lever in OFF position. Compressor belt off or broken. Compressor not functioning (if both the large and small hoses in the left-hand access panel are at the same temperature). High-pressure switch on - insufficient air flow across condenser.

Select AIR CONDITIONING position.

Replace belt. See your John Deere dealer.

Clean condenser. Check fan belt condition. Check engine fan speed belt position. Check rotary screen function. If this does not correct problem, see your John Deere dealer. Clean filters. Check cab fan operation. If this does not correct problem, see your John Deere dealer. Move slide lever to warmer setting.

Low-pressure switch on - insufficient air flow across evaporator.

Low-pressure switch on - low outside air temperature. Low-pressure switch on - insufficient refrigerant level (bubbles in sight glass). Heater valve partially on - (with temperature lever in max. air conditioning, feel both heater hoses on right-hand side of cab. If both are warm, valve is open). Compressor clutch cycles excessively or compressor stays off up to 15 minutes. Evaporator icing.

See your John Deere dealer.

Adjust control rod through tray opening. Move lever to OFF. Loosen set screw in balljoint and when applying slight pressure down on rod, tighten balljoint. Adjust controls correctly. See Operators Station section. Open louvers. Clean filters. Move lever to warmer setting.

Continued on next page

HX,AG,SF7240 1915APR981/2
101801

165-16

PN=458

Trouble Shooting
Symptom Problem

F
Solution

Bad smell (foul odor) in cab.

Plugged drain tube. Dirty filters. Dirty cab.

Blow out condensate tube and clean pan under evaporator. Clean filters. Vacuum out cab. Be certain weep valve in condensate drain tube is installed.

HX,AG,SF7240 1915APR982/2

165-17

101801

PN=459

Storage
Preparing Combine for Storage
Swing out condenser and oil cooler. Clean radiator with air, water or a vacuum cleaner. Clean condenser and oil cooler after cleaning radiator. Clean the charge air cooler. Every 60 to 90 days start engine and turn air conditioning on. Run engine at low idle for several minutes for compressor seal lubrication. Outside temperature should be above 5C (40F) for proper air conditioning operation. Clean outside of engine with a safe solvent. CAUTION: Do not use gasoline. Clean inside of air cleaner and install new elements. With engine warm, drain crankcase. Replace filter and fill with correct oil. Add 0.66L (22 oz.) of corrosion inhibitor to crankcase. Run engine to circulate. Drain, flush, and refill cooling system with 50/50 mixture of antifreeze and water. See Lubrication and Maintenance section. Add .94L (1 qt.) of RE23182 coolant conditioner. Run engine to circulate. Drain water separator. Remove and clean batteries. Store them in a cool dry place and keep them charged. Clean combine inside and out. Leave elevator doors and drain covers open. Cycle concave up and down several times to prevent material buildup in the concave area. IMPORTANT: Do not use high pressure washer spray directly on bearings. High pressure water can get past most seals and cause damage. Dry these areas, then lube and run combine. Repaint areas where needed.

Continued on next page

OUO6075,000175E 1930MAY011/2
101801

170-1

PN=460

Storage
Lubricate combine and grease adjusting bolt threads. Perform all 400 hour (yearly) service. Fill fuel tank to prevent condensation.

OUO6075,000175E 1930MAY012/2

Removing Combine from Storage


Reconnect and/or charge batteries. Check oil and coolant levels. Inspect for leaks and add oil and coolant if needed. Close elevator doors and drain hole. Review operators manual. Check drive belt tensions. Adjust spring loaded idlers to the gauge. Check tire inflation. Check coolant in sight glass. If there are bubbles in the sight glass after the compressor has run for 30 seconds or more, see your John Deere dealer.

OUO1035,0000369 1920SEP001/1

170-2

101801

PN=461

Specifications
Operating Speeds
Speeds shown are average and can vary from machine to machine. Speeds are rated at high idle with separator engaged, no load.

Continued on next page

OUO6075,000191E 1928JUN011/2

175-1

101801

PN=462

Specifications
Engine:
Slow Idle
Slow Idle
Mid Speed
Mid Speed
Fast Idle
Fast Idle
Rated Speed
Rated Speed
Separator Drive Shaft Speed
Power Separator Speed
Main Countershaft Speed
Cylinder Speed:
Standard Range
Dual Range
Feeder House Lower Shaft:
Fixed Speed
Secondary Countershaft:
Cleaning Fan:
Standard
Clean Grain Elevator
Tailings Elevator
Shoe Crankshaft
Straw Walkers
Unloading Auger Countershaft
Loading Auger:
9540, 9640, 9560 and 9580
9660 and 9680
Inner Grain Tank Unloading Augers:
Front
Rear
Vertical and Horizontal Unloading Augers:
Vertical High
Vertical Low
Horizontal High
Horizontal Low
Fine Cut Chopper:
Speed
Straw Spreader Shaft
Shoe Grain Supply Augers Shaft

9540 (1300 rpm)


9560, 9580, 9640, 9660, 9680 (1200 rpm)
9540 (1850 rpm)
9560, 9580, 9640, 9660, 9680 (1680 rpm)
9540 (2550 rpm)
9560, 9580, 9640, 9660, 9680 (2340 rpm)
9540 (2300 rpm)
9560, 9640, 9580, 9660, 9680 (2100 rpm)
1546 rpm
150 rpm
1546 rpm

350 - 950 rpm


200 - 475 rpm

520 rpm
530 rpm

750-1600 rpm
400 rpm
430 rpm
280 rpm
150 rpm
1060 rpm

430 rpm
430 rpm

405 rpm
390 rpm

440 rpm
360 rpm
405 rpm
380 rpm

3620 rpm
235 rpm
405 rpm

OUO6075,000191E 1928JUN012/2

175-2

101801

PN=463

Specifications

Whole Body Vibration


The weighted root mean square acceleration to which the whole body is subjected to, ranges from 0.35 to 0.55 m/s as measured on a representative machine during field operations, and analyzed in accordance with ISO 2631. These acceleration values depend on the roughness of the ground, the speeds at which the combine and separator mechanisms are operated, the maintenance of the machine and the operators experience, weight and driving habits.

HX,CTSSP,C 1922DEC951/1

Sound Level
The A-weight sound pressure levels inside the operators station ranged from 74.3 76.2 dB(A) as measured on several representative machines in accordance with ISO 5131. The sound pressure level depends upon the engine speed and load, separator settings, field and crop conditions and the type of platform used.

OUO6075,0000245 1907DEC001/1

Turning Radius
Combine Model
9540, 9640, 9560 and 9580
9660, 9680

Rear Wheel Tread Width


3.1 m (10 ft. 2 in.)
3.6 m (11 ft. 8 in.)

Turning Radius
7.4 m (24 ft. 2 in.)
7.1 m (22 ft. 9 in.)

HX,AG,SF7249 1910JUN991/1

175-3

101801

PN=464

Specifications

Specifications - 9540 Combine Only


Engine: Make:
Model
Type
Brake Horsepower
Displacement
Bore and Stroke:
Firing Order
Air Cleaner
Thermostats (Two)
Electrical System:
Transmission:
Brakes:
Cylinder:
Concave:
Beater:
Second Concave:
a

John Deere
6068HZ
six-cylinder, in line, valve-in-head, diesel turbocharged
9540 151 kW (202 hp)
6.8 L (414 cu. in.)
107 x 110 mm (4.20 x 4.33 in.)
1-5-3-6-2-4
Dry Type with Safety Element
82C (180F)
12 volt, negative ground with 120 amp alternator
three speeds
hydraulic shoe

Number of rasp bars:


Types
Number of wings
Type
Number of grate bars:

10
13 open bar
8
open bar two-position adjustable
10
adjustable
straw walkers
Lip
5
Retractable, in-line
15
7,500 L (213 bu.)
4,200 L/min. (120 bu./min.)
10,700 kg (23,594 lb.)
700 L (185 gal.)
36 L (38 U.S. qts.)
18.9 L (20 U.S. qts.)
9.6 L (10 U.S. qts.)
8.5 L (9 U.S. qts.)
0.9 L (2 U.S. pts.)
1.2 L (2-1/2 U.S. pts.)
400 cc (14 oz.)
1.9 L (2 U.S. qts.)
16 L (17 U.S. qts.)

Finger Bar:
Separator:
Straw Walkers:

Type
Type
Type
Number of walkers:

Power Separator:

Type
Number of fingers:

Grain Tank:

Capacity
Average Unloading Rate

Weight:
Capacities:

Less header (base equipment on a Corn Combine)


Fuel tank
Cooling system (with heater)
Engine crankcase (with filter)
Transmission
Final Drives (each)
Feeder House Reverser Gearcase
Primary Countershaft Gearcase
Beater/Straw Walker Drive Gearcase
Dual-Range Cylinder Drive Gearcase
Engine Gearcase

The hp/kW rating on the engine emissions certificate label specifies the gross engine hp/kW, which is flywheel power without fan. In most applications this will not be the same rating as advertised vehicle hp/kW rating.

Continued on next page

OUO6075,0001923 1928JUN011/2
101801

175-4

PN=465

Specifications
Loading Auger Gearcase
Hydraulic/Hydrostatic Reservoir

3.8 L (4 U.S. qts.)


34 L (36 U.S. qts.)

OUO6075,0001923 1928JUN012/2

175-5

101801

PN=466

Specifications

Specifications - 9560, 9580, 9640, 9660, 9680 Combines


Engine: Make:
Model
Type
Brake Horsepower
a

John Deere
6081HZ
six-cylinder, in line, valve-in-head, diesel turbocharged
9560 175 kW (235 hp) 9580, 9640 200 kW (268 hp) 9660 222 kW (298 hp) 9680 247 kW (331 hp)
8.1 L (499 cu. in.)
116 x 129 mm (4.56 x 5.08 in.)
1-5-3-6-2-4
Dry Type with Safety Element
82C (180F)
12 volt, negative ground with 120 amp alternator
three speeds
hydraulic shoe

Displacement
Bore and Stroke:
Firing Order
Air Cleaner
Thermostats (Two)
Electrical System:
Transmission:
Brakes:
Cylinder:
Concave:
Beater:
Second Concave:

Number of rasp bars:


Types
Number of wings
Type
Number of grate bars:

10
13 open bar
8
open bar two-position adjustable
10
adjustable
straw walkers
Lip
5
6
Retractable, in-line
15 18
7,500 L (213 bu.)
8,000 L (227 bu.)
8,000 L (227 bu.)
9,000 L (255 bu.)
11,000 L (312 bu.)
4200 L/min. (120 bu./min.)
11,230 kg (24,762 lb.)
700 L (185 gal.)
40 L (42 U.S. qts.)
45 L (48 U.S. qts.)

Finger Bar:
Separator:
Straw Walkers:

Type
Type
Type
Number of walkers: (9560, 9580)
Number of walkers: (9640, 9660, 9680)

Power Separator:

Type
Number of fingers: 9560, 9580 9640, 9660, 9680

Grain Tank:

Capacity (9560)
Capacity (9580)
Capacity (9640)
Capacity (9660)
Capacity (9680)
Average Unloading Rate

Weights:
Capacities:

Less header (base equipment on a Corn Combine)


Fuel Tank
Cooling system (with heater) (9560, 9580, 9640)
Cooling system (with heater) (9660, 9680)

a The hp/kW rating on the engine emissions certificate label specifies the gross engine hp/kW, which is flywheel power without fan. In most applications this will not be the same rating as advertised vehicle hp/kW rating.

Continued on next page

OUO6075,0001922 1928JUN011/2
101801

175-6

PN=467

Specifications
Engine crankcase (with filter)
Transmission
Final Drives (each)
Feeder House Reverser Gearcase
Primary Countershaft Gearcase
Beater/Straw Walker Drive Gearcase
Dual-Range Cylinder Drive Gearcase
Engine Gearcase
Loading Auger Gearcase
Hydraulic/Hydrostatic Reservoir

28.5 L (30 U.S. qts.)


9.6 L (10 U.S. qts.)
8.5 L (9 U.S. qts.)
0.9 L (2 U.S. pts.)
1.2 L (2-1/2 U.S. pts.)
400 cc (14 oz.)
1.9 L (2 U.S. qts.)
16 L (17 U.S. qts.)
3.8 L (4 U.S. qts.)
34 L (36 U.S. qts.)

OUO6075,0001922 1928JUN012/2

Dimensions
DIMENSION
A
B
C
D
E
F
G
H
I
J

9540, 9560, 9580, 9640, 9660, 9680


8.98 m (29 ft. 5 in.) w/17 ft. Unloading Auger
9.89 m (32 ft. 5 in.) w/20 ft. Unloading Auger
8.45 m (27 ft. 8 in.)
9.10 m (29 ft. 10 in.)
3.94 m (12 ft. 11 in.)
3.93 m (12 ft. 9 in.)
6.15 m (2 ft. 0 in.)
3.77 m (12 ft. 4 in.)
4.20 m (13.8 ft.) w/ 6096 mm (20 ft. unloading auger)
4.04 m (13.3 ft.) w/ (5182 mm (17 ft.) unloading auger)
3.92 m (12.9 ft.) w/ (5.18 m (17 ft.) unloading auger) 4.07 m (13.4 ft.) w/ (6.10 m (20 ft.) unloading auger)
3.66 m (11 ft. 11 in.) w/ 480/80R26 Tiresa
3.77 m (12 ft. 5 in.) w/ 800/65R32 Tires

9540HM, 9560HM, 9580HM, 9640HM, 9660HM, 9680HM


8.98 m (29 ft. 5 in.) w/17 ft. Unloading Auger
9.89 m (32 ft. 5 in.) w/20 ft. Unloading Auger
8.53 m (27 ft. 11 in.)
9.14 m (29 ft. 11 in.)
3.78 m (12 ft. 5 in.)
4.00 m (13 ft. 1 in.)
5.90 m (2 ft. 0 in.)
3.80 m (12 ft. 5 in.)
4.20 m (13.8 ft.) w/ 6096 mm (20 ft. unloading auger)
4.04 m (13.3 ft.) w/ (5182 mm (17 ft.) unloading auger)
3.92 m (12.9 ft.) w/ (5.18 m (17 ft.) unloading auger) 4.07 m (13.4 ft.) w/ (6.10 m (20 ft.) unloading auger)
3.66 m (11 ft. 11 in.) w/ 480/80R26 Tiresa
3.77 m (12 ft. 5 in.) w/ 800/65R32 Tires

L
M
a

Rear axles can be adjusted to various widths.

OUO6075,00019D8 1909AUG011/1

175-7

101801

PN=468

Specifications

Dimension Reference Points

OUO6089,000004F 1929JUN011/1

175-8

101801

PN=469

ZX25212

UN29JUN01

Specifications

Metric Bolt and Cap Screw Torque Values

Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8
Size
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
a
b

Class 8.8 or 9.8


b

Class 10.9
Lubricated Nm (lb-ft)
13 (9.5)
32 (23.5)
63 (46)
110 (80)
175 (130)
275 (200)
375 (275)
530 (390)
725 (535)
920 (680)
1350 (1000)
1850 (1350)
2500 (1850)
3200 (2350)
a

Class 12.9
b

Lubricated Nm (lb-ft)
4.7 (3.5)
11.5 (8.5)
23 (17)
40 (29.5)
63 (46)
100 (74)
135 (100)
190 (140)
265 (195)
330 (245)
490 (360)
660 (490)
900 (665)

Dry Nm (lb-ft)
6 (4.4)
14.5 (10.7)
29 (21)
50 (37)
80 (59)
125 (92)
170 (125)
245 (180)
330 (245)
425 (315)
625 (460)
850 (625)
1150 (850)
1450 (1075)

Lubricated Nm (lb-ft)
9 (6.6)
22 (16)
43 (32)
75 (55)
120 (88)
190 (140)
265 (195)
375 (275)
510 (375)
650 (480)
950 (700)

Dry Nm (lb-ft)
11.5 (8.5)
28 (20.5)
55 (40)
95 (70)
150 (110)
240 (175)
330 (245)
475 (350)
650 (480)
820 (600)
1200 (885)
1630 (1200)
2200 (1625)
2850 (2100)

Dry Nm (lb-ft)
16.5 (12.2)
40 (29.5)
80 (59)
140 (105)
220 (165)
350 (255)
475 (350)
675 (500)
920 (680)
1150 (850)
1700 (1250)
2300 (1700)
3150 (2325)
4050 (3000)

Lubricateda Nm (lb-ft)
15.5 (11.5)
37 (27.5)
75 (55)
130 (95)
205 (150)
320 (235)
440 (325)
625 (460)
850 (625)
1080 (800)
1580 (1160)
2140 (1580)
2900 (2150)
3750 (2770)

Dryb Nm (lb-ft)
19.5 (14.5)
47 (35)
95 (70)
165 (120)
260 (190)
400 (300)
560 (410)
790 (580)
1080 (800)
1350 (1000)
2000 (1475)
2700 (2000)
3700 (2730)
4750 (3500)

1290 (950)
1750 (1300)
2250 (1650)

1150 (850)

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
"Dry" means plain or zinc plated without any lubrication.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.

DX,TORQ2 1901OCT991/1

175-9

101801

PN=470

TORQ2

UN07SEP99

Specifications

Unified Inch Bolt and Cap Screw Torque Values

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark)
Size
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2

Grade 2a (No Mark)


Lubricated Nm (lb-ft)
6 (4.4)
12 (9)
22 (16)
35 (26)
53 (39)
76 (56)
105 (77)
190 (140)
190 (140)
285 (210)
400 (300)
570 (420)
750 (550)
990 (730)
b

Grade 5, 5.1 or 5.2


Lubricated Nm (lb-ft)
9.5 (7)
19.5 (14.5)
35 (26)
56 (41)
85 (63)
125 (92)
170 (125)
300 (220)
490 (360)
730 (540)
910 (670)
1280 (945)
1700 (1250)
2250 (1650)
b

Grade 8 or 8.2
Lubricatedb Nm (lb-ft)
13.5 (10)
28 (20.5)
49 (36)
80 (59)
120 (88)
175 (130)
240 (175)
425 (315)
690 (510)
1030 (760)
1450 (1075)
2050 (1500)
2700 (2000)
3600 (2650)

Lubricated Nm (lb-ft)
3.8 (2.8)
7.7 (5.7)
13.5 (10)
22 (16)
34 (25)
48 (35.5)
67 (49)
120 (88)
190 (140)
285 (210)
400 (300)
570 (420)
750 (550)
990 (730)

Dry Nm (lb-ft)
4.7 (3.5)
9.8 (7.2)
17.5 (13)
28 (20.5)
42 (31)
60 (45)
85 (63)
150 (110)
240 (175)
360 (265)
510 (375)
725 (535)
950 (700)
1250 (930)

Dry Nm (lb-ft)
7.5 (5.5)
15.5 (11.5)
27.5 (20)
44 (32.5)
67 (49)
95 (70)
135 (100)
240 (175)
240 (175)
360 (265)
510 (375)
725 (535)
950 (700)
1250 (930)

Dry Nm (lb-ft)
12 (9)
25 (18.5)
44 (32.5)
70 (52)
110 (80)
155 (115)
215 (160)
380 (280)
615 (455)
920 (680)
1150 (850)
1630 (1200)
2140 (1580)
2850 (2100)

Dryc Nm (lb-ft)
17 (12.5)
35 (26)
63 (46)
100 (74)
155 (115)
220 (165)
305 (225)
540 (400)
870 (640)
1300 (960)
1850 (1350)
2600 (1920)
3400 (2500)
4550 (3350)

a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length.
b
c

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
"Dry" means plain or zinc plated without any lubrication.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

DX,TORQ1 1901OCT991/1

175-10

101801

PN=471

TORQ1A

UN27SEP99

Specifications

Safety Note Regarding the Subsequent Installation of Electrical and Electronic Appliances and/or Components
The machine is equipped with electronic components whose function may be influenced by electromagnetic radiation from other appliances. Such influences may be hazardous, so take the following safety instructions into account: If electrical and electronic appliances are subsequently installed on the machine and connected to the on board system, the user must verify whether the installation affects the electronics or other components. This applies particularly to: Area counter Personal Computer GPS (Global Positioning System) receiver In particular, subsequently installed electrical/electronic components must comply with the relevant edition of EMC Directive 89/336/EEC, and be CE marked. If mobile communication systems (e.g. radio communication, telephone) are to be installed subsequently, the following extra requirements must be met: Only devices with an approval complying with the valid national regulation (i.e. BZT approval in Germany) shall be installed; The device shall be installed securely; Portable or mobile devices may be operated in the vehicle only if connected to a fixed outside antenna; Transmitters shall be installed separately from the vehicles electronics; The antenna must be installed in a professional manner, with a good ground connection between the antenna and the vehicle ground. Wiring, installation and maximum permissible current supply must be as stated in the installation instructions of the machine manufacturer.

175-11

OUO6075,00019D2 1907AUG011/1

101801

PN=472

Specifications

F
ZX08678,000001B 1921JUN011/1
101801

Declaration of Conformity
John Deere Werke Zweibru cken Homburger Strae 117 D-66482 Zweibru cken The Combine: Models .............................. 9540, 9540HM, 9560, 9560HM, 9580, 9580HM, 9640, 9640HM, 9660, 9660HM, 9680 und 9680HM comply with the EU provisions: 98/37/EEC ..............Machine Directive 89/336/EEC ............EMC Directive and EN632 ............ Combines and Forage Harvesters Zweibru cken 01 May 2001
UN02JUL01

175-12

PN=473

ZXCE600R

Machine Identification Numbers


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.

OUO6075,000192A 1903JUL011/1

Combine Type Plate


AProduct Identification Number BHomologation Number (Certain countries only) CModel DYear of Production EVersion (Certain countries only) FEngine Power GAbsorption Coefficient HFrench Homologation Purpose Only JPermissible Drawbar Load KPermissible Trailer Load LPermissible Rear Axle Load MPermissible Front Axle Load NPermissible Total Weight

OUO6075,000192B 1903JUL011/1

Engine Serial Number


Located on rear side of engine, next to the oil filter.

OUO6075,0001929 1903JUL011/1

180-1

101801

PN=474

H69076

UN03JUL01

ZX017478

UN17JUN99

Machine Identification Numbers

Hydrostatic Drive Unit Pump


Located on the side of the pump section.

OUO6075,000192C 1903JUL011/1

Hydrostatic Drive Unit Motor


Located on top of the motor section.

OUO6075,000192D 1903JUL011/1

2 Speed 4-Wheel Drive Motor


Located on top of motor.

OUO6075,0001762 1930MAY011/1

180-2

101801

PN=475

H43678

UN10JUL91

H69087

UN16JUL01

H69086

UN16JUL01

Machine Identification Numbers

Engine Gearcase
Located on the back side.

HX,AG,SF7262 1911SEP921/1

Transmission
Located on the side of the transmission.

HX,AG,SF7263 1910OCT971/1

180-3

101801

PN=476

H69088

UN16JUL01

H44937

UN03AUG92

Index
Page Page

A
Access cover for clean grain Eeevator . . . . . . . 90-17 Accessory drive belt, replace . . . . . . . . . . . . . 120-15 Accumulator (general information) . . . . . . . . . . 150-3 Activation, buttons . . . . . . . . . . . . . . . . . . . . . . 20-29 Adjust rotary screen knife comb . . . . . . . . . . . 120-20 Adjust swing cylinder eyebolt . . . . . . . . .100-7, 140-4 Adjust, automatic combine . . . . . . . . . . . . . . . . . 70-1 Adjusting Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . 55-3 Adjusting fore/aft tilt . . . . . . . . . . . . . . . . . . . . . . 85-4 Adjusting precleaner . . . . . . . . . . . . . . . . . . . . . 90-15 Adjusting spreader disk vanes . . . . . . . . . . . . . . 95-5 Adjustment, clean grain elevator belt . . . . . . . 130-14 Adjustment, second concave . . . . . . . . . . . . . . 130-6 Air conditioning precautions, observing. . . . . . . 160-1 Air conditioning, troubleshooting . . . . . . . . . . . 165-16 Aligning, cylinder drive . . . . . . . . . . . . . . . . . . . 130-2 Alternator wiring . . . . . . . . . . . . . . . . . . . . . . . 145-17 Angle sensor calibration . . . . . . . . . . . . . . . . . . 30-28 Antenna Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-18 Area counter enable calibration . . . . . . . . . . . . 30-46 Area counter operation . . . . . . . . . . . . . . . . . . . 25-40 Armrest adjustment . . . . . . . . . . . . . . . . . . . . . 35-10 Armrest console, cleaning fan switch . . . . . . . . 20-19 Armrest console, leveling control switch . . . . . . 20-20 Armrest console, separator speed switch . . . . . 20-19 As required, lubrication. . . . . . . . . . . . 110-32, 110-33 Auger drive chain, uppertailings, adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 130-17 Auger support adjustment. . . . . . . . . . . .100-7, 140-4 Automatic calibration, automatic combine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-5 Automatic combine adjust display. . . . . . . . . . . . 70-3 Automatic combine adjust system. . . . . . . . . . . . 70-1 Automatic combine adjust, crops . . . . . . . . . . . . 70-2 Automatic leveling control switch . . . . . . . . . . . 20-21

Belt adjustment, tailings elevator . . . . . . . . . . 130-16 Belt cylinder, replace . . . . . . . . . . . . . . . . . . . . 130-5 Belt replacement for clean grain elevator . . . . 130-14 Belt shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-2 Belt, beater, replacement . . . . . . . . . . . . . . . . . 130-7 Belt, chopper, replacing . . . . . . . . . . . . . . . . . . 135-3 Belt, cleaning fan, replacement. . . . . . . . . . . . 130-13 Belt, cylinder imtermediate, replace . . . . . . . . . 130-4 Belt, elevator,replacement . . . . . . . . . . . . . . . 130-15 Belt, feeder house fixed speed Adjusting . . . . . . . . . . . . . . . . . . . . . . .85-11, 125-4 Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 125-2 Belt, rotary screen, routing . . . . . . . . . . . . . . . 120-17 Belt, secondary countershaft, replacement . . . . 130-8 Belt, secondary countershaft,adjustment . . . . . 130-7 Bleeding fuel lines . . . . . . . . . . . . . . . . . . . . . . 120-7 Bolt torque Drive wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2 Bolt torque, rear wheel . . . . . . . . . . . . . . . . . . . . 60-2 Brake fluid . . . . . . . . . . . . . . . . . . . . . . .105-8, 155-1 Brake pedals . . . . . . . . . . . . . . . . . . . . . .35-12, 55-2 Brake, parking, manual. . . . . . . . . . . . . . . . . . . . 55-1 Brakes, troubleshooting . . . . . . . . . . . . . . . . . 165-10 Break-in check - first 100 hours . . . . . . . . . . . . . 50-8 Break-in check, after 100 hours . . . . . . . . . . . . . 50-8 Bulb replacement Dome and console lights. . . . . . . . . . . . . . . 145-14 Bulbs, replacing . . . . . . . . . . . . . . . . . . . . . . . . 145-9

C
Cab ladder positions. . . . . . . . . . . . . . . . . . . . . . 35-1 Cab landing safety chains . . . . . . . . . . . . . . . . . 35-2 Calibration switch . . . . . . . . . . . . . . . . . . . . . . . 25-28 Calibration, clock . . . . . . . . . . . . . . . . . . . . . . . 30-59 Calibration, header . . . . . . . . . . . . . . . . . . . . . . 30-23 Capacities; lubricant, fuel, cooling system . . . . 105-9 Central electronics box (CEB) Relay location . . . . . . . . . . . . . . . . . . . . . . . . 145-5 Chaff spreader . . . . . . . . . . . . . . . . . . . . . . . . . . 95-3 Chaffer finger bar cover . . . . . . . . . . . . . . . . . . 90-16 Chaffer fingers, storage . . . . . . . . . . . . . . . . . . 90-14 Chaffer fingers, using . . . . . . . . . . . . . . . . . . . . 90-15 Chaffer, adjusting . . . . . . . . . . . . . . . . . . . . . . . 90-16 Chain adjustment, clean grain elevator. . . . . . 130-15 Chain links, conveyor Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-6 Chain links, conveyor, removing . . . . . . . . . . . . 125-3 Chain, drive, feeder conveyor, adjusting . . . . . . . 85-8 Chain, drive, feeder conveyor,adjusting . . . . . . 125-3

B
Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-1 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-4 Battery, booster, connecting . . . . . . . . . . . . . . . 145-4 Beater belt replacement . . . . . . . . . . . . . . . . . . 130-7 Beater speed, 75 percent, optional . . . . . . . . . . 90-13 Beater-belt idler adjustment . . . . . . . . . . . . . . . 130-6 Belt adjustment, straw walker gearcase . . . . . 130-10

Index-1

101801

PN=1

Index

Page

Page

Chain, drive, tailings elevator,adjustment . . . . 130-16 Chain, feeder conveyor, adjusting . . . . . . . . . . . 85-5 Chain, paddle, tailings elevator,adjustment. . . 130-17 Check engine oil. . . . . . . . . . . . . . . . . . . . . . . . 120-4 Checking Battery electrolyte level . . . . . . . . . . . . . . . . . 145-2 Battery specific gravity . . . . . . . . . . . . . . . . . 145-3 Chop to drop . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-3 Chopper Adjusting vanes. . . . . . . . . . . . . . . . . . . . . . . . 95-2 Chopper vane angle calibration . . . . . . . . . . . . 30-56 Chopper vane switch . . . . . . . . . . . . . . . . . . . . 20-20 Chopper vanes . . . . . . . . . . . . . . . . . . . . . . . . . . 95-2 Chopper, (general information) . . . . . . . . . . . . . . 95-1 Clean grain elevator belt,adjustment. . . . . . . . 130-14 Clean grain elevator chain adjustment . . . . . . 130-15 Clean grain top access cover . . . . . . . . . . . . . . 90-17 Cleaning combine. . . . . . . . . . . . . . . . . . . . . . 110-34 Cleaning fan drive, slow-speed(optional) . . . . . 90-14 Cleaning fan speed switch . . . . . . . . . . . . . . . . 20-19 Cleaning out the combine. . . . . . . . . . . . . . . . . . 80-1 Cleaning shoe auger gear, adjusting . . . . . . . 130-11 Cleaning shoe light bulb replacement . . . . . . . 145-13 Cleaning shoe lights . . . . . . . . . . . . . . . . . . . . . 40-12 Cleaning, panels composite Panels, cleaning . . . . . . . . . . . . . . . . . . . . . . 115-5 Clear service indicator . . . . . . . . . . . . . . . . . . . 30-62 CLIMATRAK air conditioning system- . . . . . . . . 160-1 Clutch, electromagnetic, header drive. . . . . . . 145-17 Clutch, slip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-9 Clutch, slip, tailings elevator . . . . . . . . . . . . . . . 90-18 Cold weather operation . . . . . . . . . . . . . . . . . . 50-10 Combine Removing from storage. . . . . . . . . . . . . . . . . 170-2 Combine and corn head check list . . . . . . . . . . . 75-6 Combine cleanout. . . . . . . . . . . . . . . . . . . . . . 110-34 COMFORTCOMMAND air suspension seat . . . . 35-8 Compressor drive belt replacement . . . . . . . . . 160-5 Concave clearance switch . . . . . . . . . . . . . . . . 20-18 Concave closure plates, front . . . . . . . . . . . . . . 90-11 Concave closure plates, rear . . . . . . . . . . . . . . 90-11 Concave sensor zero calibration. . . . . . . . . . . . 30-43 Condenser, cleaning. . . . . . . . . . . . . . . . . . . . . 160-3 Control console adjustment . . . . . . . . . . . . . . . 35-10 Control switches, triple display tachometer . . . . 25-42 Controls and instruments Armrest control panel . . . . . . . . . . . . . . . . . . . 20-3 Corner post . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6 Engine speed switch . . . . . . . . . . . . . . . . . . . 20-14 Gear shift lever . . . . . . . . . . . . . . . . . . . . . . . 20-35 General view. . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36

Mirror heater tumbler switch . . . . . . . . . . . . . 20-34 Multi-function lever . . . . . . . . . . . . . . . . . . . . . 20-5 Outside mirror control switch. . . . . . . . . . . . . 20-34 Roof console. . . . . . . . . . . . . . . . . . . . . . . . . . 20-8 Start switch . . . . . . . . . . . . . . . . . . . . . .20-37, 45-6 Switch and knob colors . . . . . . . . . . . . . . . . . . 20-2 Coolant Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 105-3 Coolant conditioner. . . . . . . . . . . . . . . . . . . . . . 105-4 Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2 Cooler, after, cleaning . . . . . . . . . . . . . . . . . . 120-19 Cooling compartment . . . . . . . . . . . . . . . . . . . . . 35-7 Cooling system, drain . . . . . . . . . . . . . . . . . . . 120-10 Cooling system, winterizing . . . . . . . . . . . . . . 120-12 Corn kernel loss . . . . . . . . . . . . . . . . . . . . . . . . . 75-7 Corner post, header width . . . . . . . . . . . . . . . . 25-20 Corner post, lateral tilt . . . . . . . . . . . . . . . . . . . 25-22 Corner Post, reel position resume . . . . . . . . . . 25-26 Corner post, return to cut . . . . . . . . . . . . . . . . . 25-18 Counter knife bank replacement . . . . . . . . . . . . 135-3 Crankshaft damper, replace . . . . . . . . . . . . . . 110-34 Crop settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1 Crops, automatic combine adjust . . . . . . . . . . . . 70-2 Cross auger drive shear bolt . . . . . . . . . . . . . . 100-5 Cross auger drive, grain tank,adjustment . . . . . 140-1 Curtains, separator . . . . . . . . . . . . . . . . . . . . . . 90-13 Cylinder access door, setting . . . . . . . . . . . . . . . 90-9 Cylinder belt idler adjustment . . . . . . . . . . . . . . 130-3 Cylinder belt, replace . . . . . . . . . . . . . . . . . . . . 130-5 Cylinder drive gap, adjusting . . . . . . . . . . . . . . 130-1 Cylinder drive, aligning . . . . . . . . . . . . . . . . . . . 130-2 Cylinder eyebolt adjustment . . . . . . . . . .100-7, 140-4 Cylinder intermediate belt, replace . . . . . . . . . . 130-4 Cylinder vibration . . . . . . . . . . . . . . . . . . . . . . . . 90-9 Cylinder, hydraulic, safety stop . . . . . . . . . . . . . . 85-1 Cylinder, power unplugging of . . . . . . . . . . . . . . 90-8

D
Deck plate sensor zero, calibration. . . . . . . . . . 30-51 Diagnostic addresses . . . . . . . . . . . . . . . . . . . . . 30-1 Diagnostic icon . . . . . . . . . . . . . . . . . . . . . . . . . 25-48 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . 30-2 Armrest Control Unit . . . . . . . . . . . . . . . . . . . 30-12 Cornerpost Control Unit . . . . . . . . . . . . . . . . 30-14 Engine Control Unit. . . . . . . . . . . . . . . . . . . . . 30-7 Header Control Unit . . . . . . . . . . . . . . . . . . . 30-16 Left Control Unit . . . . . . . . . . . . . . . . . . . . . . 30-19 Left Control Unit 2. . . . . . . . . . . . . . . . . . . . . 30-20 Right Control Unit . . . . . . . . . . . . . . . . . . . . . 30-18

Index-2

101801

PN=2

Index

Page

Page

Tailings Master Sensor . . . . . . . . . . . . . . . . . 30-15 DIAL-A-SPEED. . . . . . . . . . . . . . . . . . . . . . . . . 25-21 DIAL-A-SPEED control switch . . . . . . . . . . . . . 20-12 Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . 105-5 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-1 Dimension reference points Specifications . . . . . . . . . . . . . . . . . . . . . . . . 175-8 Dimensions Specifications . . . . . . . . . . . . . . . . . . . . . . . . 175-7 Dimmer switch . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2 Disk vane adjustments . . . . . . . . . . . . . . . . . . . . 95-5 Door, access, straw walkers . . . . . . . . . . . . . . . 90-12 Door, cylinder access . . . . . . . . . . . . . . . . . . . . . 85-2 Door, engine compartment . . . . . . . . . . . . . . . . 120-1 Door, feeder house,bottom . . . . . . . . . . . . . . . . . 85-3 Doors, feeder house . . . . . . . . . . . . . . . . . . . . . . 85-2 Drain holes, grain tank . . . . . . . . . . . . . . . . . . . 100-1 Drive adjustment for unloading auger . . . . . . . . 140-2 Drive belt (6.8 Engine) Routing (6.8 Liter Engine) . . . . . . . . .120-14, 160-4 Drive belt (8.1 Engine) Routing (8.1 Liter Engine) . . . . . . . . .120-14, 160-4 Drive belt, unloading auger, replacement . . . . . 140-1 Drive chain, auger, upper tailings, adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 130-17 Drive chain, feeder conveyor, adjusting . . . . . . .85-8, 125-3 Drive chain, tailings elevator, adjustment . . . . 130-16 Drive cylinder, unloading auger, adjustment . . .100-6, 140-3 Drive cylinder, unloading auger,replacing . . . . .100-6, 140-4 Drive wheel starter stud . . . . . . . . . . . . . . . . . . . 60-4 Drive, cleaning fan, slow-speed (optional) . . . . 90-14 Drive, direct, high-range . . . . . . . . . . . . . . . . . . . 90-6 Drives, cylinder, Dual-Range POSI- TORQ . . . . 90-4 Drives, left-hand . . . . . . . . . . . . . . . . . . . . . . . . . 90-1 Drives, right-hand . . . . . . . . . . . . . . . . . . . . . . . . 90-3 Driving the combine Adjusting engine speed. . . . . . . . . . . . . . . . . . 55-3 Engaging a gear . . . . . . . . . . . . . . . . . . . . . . . 55-2 Forward travel. . . . . . . . . . . . . . . . . . . . . . . . . 55-3 Ground speed . . . . . . . . . . . . . . . . . . . . . . . . . 55-4 Hydrostatic system . . . . . . . . . . . . . . . . . . . . . 55-5 Raising header . . . . . . . . . . . . . . . . . . . . . . . . 55-3 Reverse travel alarm. . . . . . . . . . . . . . . . . . . . 55-4 Road safety switch . . . . . . . . . . . . . . . . . . . . . 55-2 Starting the engine . . . . . . . . . . . . . . . . . . . . . 55-1 Steering and driving . . . . . . . . . . . . . . . . . . . . 55-1 Drum height adjustment . . . . . . . . . . . . . . . . . . . 85-7 Dual-range cylinder drive . . . . . . . . . . . . . . . . . . 90-5

E
Electrical system Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 145-1 Electro feeder house reverser switch . . . . . . . . 20-10 Element, cleaning . . . . . . . . . . . . . . . . . . . . . . 120-22 Element, safety, inspecting . . . . . . . . . . . . . . . 120-21 Element, washing . . . . . . . . . . . . . . . . . . . . . . 120-22 Emergency exit. . . . . . . . . . . . . . . . . . . . . .10-5, 35-6 Engine Operation in hot weather. . . . . . . . . . . . . . . . . 50-9 Engine access panel . . . . . . . . . . . . . . . . . . . . 120-2 Engine compartment relay panel Fuse identification . . . . . . . . . . . . . . . . . . . . . 145-7 Relay identification . . . . . . . . . . . . . . . . . . . . 145-8 Engine fan belt, replacing . . . . . . . . . . . . . . . . 120-13 Engine gearcase location . . . . . . . . . . . . . . . . . 180-3 Engine oil Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-4 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-5 Engine oil,check . . . . . . . . . . . . . . . . . . . . . . . . 120-4 Engine serial number . . . . . . . . . . . . . . . . . . . . 180-1 Engine, breaking in. . . . . . . . . . . . . . . . . . . . . . . 50-6 Engine, compartment, cleaning. . . . . . . . . . . . . 120-1 Engine, troubleshooting . . . . . . . . . . . . . . . . . 165-11 Engine,stopping . . . . . . . . . . . . . . . . . . . . . . . . 50-12 Engine,warming . . . . . . . . . . . . . . . . . . . . . . . . . 50-5 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2 Evaporator filter, removing . . . . . . . . . . . . . . . . 160-2 Exit lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9

F
Factory Crop2 settings, automatic calibration . . . 70-5 Factory Crop2 settings, manual calibration . . . . . 70-6 Feeder conveyor speed, changing . . . . . . . . . . . 85-7 Feeder house belt, fixed speed Adjusting . . . . . . . . . . . . . . . . . . . . . . .85-11, 125-4 Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 125-2 Feeder house conveyor float Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-6 Feeder house reaction speed knobs. . . . . . . . . 20-14 Feeder house reverser . . . . . . . . . . . . . . . . . . . 20-38 Feeder house side shields . . . . . . . . . . . . . . . . . 85-1 Feeder house top shaft sprockets . . . . . . . . . . 85-10 Feeder house, top shaft stripper adjustment. . . 85-10 Feeder house, troubleshooting . . . . . . . . . . . . . 165-1 Feeder house/reel pump belt replacement . . . 130-10 Feedplate seal support . . . . . . . . . . . . . . . . . . . . 85-3

Index-3

101801

PN=3

Index

Page

Page

Field area counter clear calibration. . . . . . . . . . 30-48 Field light, bulb replacement. . . . . . . . . . . . . . 145-11 Field lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6 Field office seat . . . . . . . . . . . . . . . . . . . . . . . . . 35-7 Field total area counter clear calibration . . . . . . 30-49 Fire extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Flaps, sunflower, straw walker . . . . . . . . . . . . . 90-14 Float calibration . . . . . . . . . . . . . . . . . . .30-37, 30-40 Float, feeder house conveyor Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-6 Fore/Aft tilt frame . . . . . . . . . . . . . . . . . . . . . . . . 85-4 Forward travel . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3 Four wheel drive switch . . . . . . . . . . . . . .20-17, 55-7 Four-wheel drive (optional), troubleshooting . . . 165-9 Fresh air filter,cleaning . . . . . . . . . . . . . . . . . . . 160-2 Front concave closure plates . . . . . . . . . . . . . . 90-11 Fuel Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-1 Fuel filter replacement . . . . . . . . . . . . . . . . . . . 120-6 Fuel filter replacement, (9540 combine) . . . . . . 120-5 Fuel filter, replacing . . . . . . . . . . . . . . . . . . . . . 120-6 Fuel level, check . . . . . . . . . . . . . . . . . . . . . . . . 45-3 Fuel lines, bleeding . . . . . . . . . . . . . . . .120-7, 120-8 Fuel system . . . . . . . . . . . . . . . . . 45-3, 120-2, 120-3 Fuel system (9540 combine) . . . . . . . . . . . . . . . 45-3 Fuel system, bleeding. . . . . . . . . . . . . . . . . . . . 120-9 Fuel tank and cap. . . . . . . . . . . . . . . . . . . . . . . 120-4 Fuel tank, draining . . . . . . . . . . . . . . . . . . . . . . 120-5 Fuel tank, filling . . . . . . . . . . . . . . . . . . . . . . . . 105-2

Grease Extreme pressure and multipurpose . . . . . . . 105-7 GREENSTAR printer . . . . . . . . . . . . . . . . .35-4, 35-5 Gull wing doors, access . . . . . . . . . . . . . . . . . . 115-1

H
Harvesting hints . . . . . . . . . . . . . . . . . . . . . . . . . 65-1 Harvesting time . . . . . . . . . . . . . . . . . . . . . . . . . 65-1 Header Raising/lowering valve. . . . . . . . . . . . . . . . . . 150-3 Header engage switch . . . . . . . . . . . . . . . . . . . 20-10 Header ground pressure. . . . . . . . . . . . . . . . . . 25-24 Header height and pressure control . . . . . . . . . 20-11 Header lift switch . . . . . . . . . . . . . . . . . . . . . . . 20-31 Header width . . . . . . . . . . . . . . . . . . . . . . . . . . 25-20 Header width calibration . . . . . . . . . . . . . . . . . . 30-21 Header, calibration . . . . . . . . . . . . . . . . . . . . . . 30-23 HEADERTRAK control display . . . . . . . . . . . . . 25-11 HEADERTRAK control module . . . . . . . . . . . . . 25-10 HEADERTRAK indicator. . . . . . . . . . . . . . . . . . 85-11 Heater, troubleshooting . . . . . . . . . . . . . . . . . 165-15 High beam indicator . . . . . . . . . . . . . . . . . . . . . . 25-7 High pressure switch . . . . . . . . . . . . . . . . . . . . 160-7 High-range direct drive . . . . . . . . . . . . . . . . . . . . 90-6 Hillmaster leveling system . . . . .20-22, 20-23, 20-24, 20-25 Hitch, trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36 Hydraulic cylinder safety stop . . . . . . . . . . . . . . 125-1 Hydraulic system (general information). . . . . . . 150-1 Hydraulic system, cleanliness. . . . . . . . . . . . . . 150-2 Hydrostatic drive unit motor . . . . . . . . . . . . . . . 180-2 Hydrostatic drive unit pump . . . . . . . . . . . . . . . 180-2 Hydrostatic ground drive, troubleshooting . . . . . 165-6 Hydrostatic oil cooler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-2 Hydrostatic oil, level . . . . . . . . . . . . . . . . . . . . . . 45-2 Hydrostatic system . . . . . . . . . . . . . . . . . . . . . . . 55-5

G
Gear case oils . . . . . . . . . . . . . . . . . . . . . . . . . 105-6 Gear shift lever. . . . . . . . . . . . . . . . . . . . . . . . . . 55-2 Gear, auger, cleaning shoe, adjusting . . . . . . 130-11 Gearshift linkage, adjusting . . . . . . . . . . . . . . . 155-1 General view of controls and instruments . . . . . . 20-1 Grain tank Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-2 Adjusting full indicator . . . . . . . . . . . . . . . . . . 100-4 Adjusting 3/4 indicator. . . . . . . . . . . . . . . . . . 100-3 Grain tank cover indicator. . . . . . . . . . . . . . . . . . 25-5 Grain tank cover switch . . . . . . . . . . . . . . . . . . 20-15 Grain tank cross auger drive adjustment . . . . . 140-1 Grain tank loading and unloading . . . . . . . . . . . 100-3 Adjusting grain tank full indicator. . . . . . . . . . 100-4 Grain tank covers . . . . . . . . . . . . . . . . . . . . . 100-2 Grain tank loading auger . . . . . . . . . . . . . . . . . 100-5 Grain tank window, cleaning. . . . . . . . . . . . . . . . 35-3

I
Idler, cylinder belt, adjustment . . . . . . . . . . . . . 130-3 Inch torque values . . . . . . . . . . . . . . . . . . . . . 175-10 Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . 20-36 Inlet panel, cab roof, cleaning. . . . . . . . . . . . . . 160-3 Internal Grain Tank Switch . . . . . . . . . . . . . . . . 100-3

Index-4

101801

PN=4

Index

Page

Page

K
Knife adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 95-3 Knife section replacement . . . . . . . . . . . . . . . . 135-1

L
Ladder, cab, positions . . . . . . . . . . . . . . . . . . . . 35-1 Ladder, engine . . . . . . . . . . . . . . . . . . . . . . . . . 100-1 Ladder, grain tank . . . . . . . . . . . . . . . . . . . . . . 100-1 Ladder, rear, and landing . . . . . . . . . . . . . . . . . 120-1 Lateral tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-22 Lateral tilt sensor cable adjustment . . . . . . . . . 30-32 Lateral, lateral tilt switch . . . . . . . . . . . . . . . . . . 20-32 Left-hand side separator side shields . . . . . . . . 115-4 Light switches. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 Light, Engine air filter . . . . . . . . . . . . . . . . . . . . . . . . 25-4 Separator drive temp. . . . . . . . . . . . . . . . . . . . 25-3 Light, auger conveyor . . . . . . . . . . . . . . . . . . . . . 25-8 Light, cab interior . . . . . . . . . . . . . . . . . . . .35-6, 40-1 Light, cylinder speed . . . . . . . . . . . . . . . . . . . . . 25-9 Light, engine oil pressure . . . . . . . . . . . . . . . . . . 25-7 Light, engine speed . . . . . . . . . . . . . . . . . . . . . . 25-9 Light, engine temperature. . . . . . . . . . . . . . . . . . 25-6 Light, grain elevator . . . . . . . . . . . . . . . . . . . . . . 25-8 Light, grain tank full . . . . . . . . . . . . . . . . . . . . . . 25-5 Light, hydraulic oil temp.. . . . . . . . . . . . . . . . . . . 25-3 Light, hydro charge pressure . . . . . . . . . . . . . . . 25-6 Light, low fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2 Light, park brake on . . . . . . . . . . . . . . . . . . . . . . 25-2 Light, separator drive filter . . . . . . . . . . . . . . . . . 25-2 Light, separator drive pressure . . . . . . . . . . . . . . 25-6 Light, straw chopper . . . . . . . . . . . . . . . . . . . . . . 25-7 Light, tailings elevator. . . . . . . . . . . . . . . . . . . . . 25-8 Light, unloading auger . . . . . . . . . . . . . . . . . . . 40-10 Lighting, exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9 Lights, cleaning shoe . . . . . . . . . . . . . . . . . . . . 40-12 Lights, field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6 Lights, grain tank, bulb replacement . . . . . . . . 145-12 Lights, head, cab, bulb replacement . . . . . . . . 145-10 Lights, road . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4 Lights, side finder, bulb replacement . . . . . . . 145-12 Lights, stubble and residue. . . . . . . . . . . . . . . . . 40-8 Lights, warning . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3 Liquid weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-4 Low pressure switch. . . . . . . . . . . . . . . . . . . . . 160-7 Low range (reduced-drive) . . . . . . . . . . . . . . . . . 90-6 Low shaft speed monitor General information. . . . . . . . . . . . . . . . . . . . 25-49

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 25-50 Lowering chopper vane board . . . . . . . . . . . . . . 95-4 Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-8 Lubrication, as required . . . . . . . . . . .110-32, 110-33 Lubrication, symbols . . . . . . . . . . . . . . . . . . . . . 110-4 Lubrication, 10 hour . . . . . . . . . . . . . . . .110-5, 110-7 Lubrication, 200 hours . . . . . . . . . . . . 110-14, 110-15 Lubrication, 2000 hours . . . . 110-29, 110-30, 110-31 Lubrication, 400 hours . . . . . 110-18, 110-19, 110-20, 110-21, 110-24, 110-25, 110-27 Lubrication, 50 hours . . . . . . . . 110-8, 110-9, 110-10, 110-11, 110-12 Lubrication,100 hours . . . . . . . . . . . . . . . . . . . 110-13

M
Machine harvesting threshold calibration . . . . . 30-33 Manual calibration, automatic calibration system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-6 Manual parking brake . . . . . . . . . . . . . . . . . . . . 35-12 Manual reel speed switch . . . . . . . . . . . . . . . . . 20-18 Manual storage. . . . . . . . . . . . . . . . . . . . . . . . . . 35-4 Metric torque values . . . . . . . . . . . . . . . . . . . . . 175-9 Mirror heater. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34 Multi-function lever, adjustable deck plate position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-29 Multi-function lever, adjustments. . . . . . . . . . . . 20-26 Multi-function lever, Reel lift/reel fore aft switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31 Multi-function Lever, stubble height control . . . . 25-16

O
Operating Grain tank covers . . . . . . . . . . . . . . . . . . . . . 100-2 Hillmaster II leveling system . . . . . . . .20-22, 20-23 Hillmaster leveling system. . . . . . . . . .20-24, 20-25 Operating speeds . . . . . . . . . . . . . . . . . . . . . . . 175-1 Operating the engine Stalling of engine . . . . . . . . . . . . . . . . . . . . . 50-12 With booster batteries . . . . . . . . . . . . . . . . . . 50-11 Operators cab Access ladder . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Armrest storage box . . . . . . . . . . . . . . . . . . . . 35-4 Cooling compartment . . . . . . . . . . . . . . . . . . . 35-5 Recirculator filter . . . . . . . . . . . . . . . . . . . . . . . 35-5 Outside mirror control switch . . . . . . . . . . . . . . 20-34

Index-5

101801

PN=5

Index

Page

Page

Overhead warning display panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1

P
Paddle chain, tailings elevator, adjustment . . . 130-17 Paddles, tailings elevator . . . . . . . . . . . . . . . . . 90-18 Panel, access,engine . . . . . . . . . . . . . . . . . . . . 120-2 Pans, extension, straw walker . . . . . . . . . . . . . 90-13 Park brakelight . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2 Parking brake, manual . . . . . . . . . . . . . . .35-12, 55-1 Personal crop settings, automatic calibration . . . 70-5 Personal crop settings, manual calibration . . . . . 70-6 Power distribution board Relay identification . . . . . . . . . . . . . . . . . . . . 145-6 Power separator . . . . . . . . . . . . . . . . . . . . . . . . 90-12 Power separator access door . . . . . . . . . . . . . . 90-12 Power shutdown procedure . . . . . . . . . . . . . . . . 75-8 Power strip electrical outlets . . . . . . . . . . . . . . . . 35-6 Pre-starting checks Checks in operators cab. . . . . . . . . . . . . . . . . 45-5 Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . 45-1 Lubricate combine. . . . . . . . . . . . . . . . . . . . . . 45-5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4 Precleaner tool storage . . . . . . . . . . . . . . . . . . 90-15 Predefind settings, automatic combine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-4 Preliminary adjustments . . . . . . . . . . . . . . . . . . 25-34 Preparing combine for storage . . . . . . . . . . . . . 170-1 Printer, GREENSTAR. . . . . . . . . . . . . . . . .35-4, 35-5 Priority Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 30-2

Reduced speed unloading system . . . . . . . . . . 100-8 Reel position resume . . . . . . . . . . . . . . . . . . . . 25-26 Reel pump, belt adjustment . . . . . . . . . . . . . . . 130-9 Relay identification Power distribution board . . . . . . . . . . . . . . . . 145-6 Removing air cleaner filters . . . . . . . . . . . . . . 120-21 Removing compressor drive belt . . . . . . . . . . . 160-5 Removing header from feeder house . . . . . . . . 85-12 Replace engine accessory drive belt . . . . . . . 120-15 Replacing counter knife bank . . . . . . . . . . . . . . 135-3 Replacing engine fan belt . . . . . . . . . . . . . . . . 120-13 Replacing power separator belt . . . . . . . . . . . . 130-9 Replacing rotary screen drive belt . . . . . . . . . 120-17 Replacing unloading auger drive cylinder . . . . .100-6, 140-4 Return to cut . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 Reverser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38 Road transport disconnect switch . . . . . . . . . . . 20-16 Road, lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4 Rotary screen knife comb, adjust . . . . . . . . . . 120-20 Rotary screen, cleaning . . . . . . . . . . . . . . . . . 120-19

S
Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Safety element, inspecting . . . . . . . . . . . . . . . 120-21 Safety rules, engine . . . . . . . . . . . . . . . . . . . . . . 50-1 Screen, rotary, cleaning . . . . . . . . . . . . . . . . . 120-19 Screens, perforated . . . . . . . . . . . . . . . . . . . . . 90-17 Seat suspension/adjustments . . . . . . . . . . . . . . . 35-9 Seat, COMFORTCOMMAND, air suspension . . . 35-8 Second concave adjustment. . . . . . . . . . . . . . . 130-6 Second concave curtain . . . . . . . . . . . . . . . . . . 90-12 Secondary countershaft belt adjustment . . . . . . 130-7 Seed loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-4 Separator countershaft strips . . . . . . . . . . . . . . 90-18 Separator curtains . . . . . . . . . . . . . . . . . . . . . . 90-13 Separator engage switch . . . . . . . . . . . . . . . . . 20-11 Separator loss, display . . . . . . . . . . . . . . . . . . . 25-33 Separator plugged . . . . . . . . . . . . . . . . . . . . . . . 25-4 Separator speed switch . . . . . . . . . . . . . . . . . . 20-19 Separator, troubleshooting . . . . . . . . . . . . . . . . 165-2 Service - electrical system Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-1 Battery handling . . . . . . . . . . . . . . . . . . . . . . 145-1 Battery service . . . . . . . . . . . . . . . . . . . . . . . 145-2 Battery switch . . . . . . . . . . . . . . . . . . . . . . . . 145-3 Checking battery electrolyte level . . . . . . . . . 145-2 Checking battery specific gravity . . . . . . . . . . 145-3 Connecting batteries . . . . . . . . . . . . . . . . . . . 145-4

Q
Quick stop switch . . . . . . . . . . . . . . . . . . . . . . . 20-26

R
Radiator, filling . . . . . . . . . . . . . . . . . . . . . . . . 120-12 Raising chopper vane board. . . . . . . . . . . . . . . . 95-4 Rate control knob . . . . . . . . . . . . . . . . . . . . . . . 20-14 Rear concave closure plates . . . . . . . . . . . . . . 90-11 Rear concave inserts . . . . . . . . . . . . . . . . . . . . 90-10 Rear residue discharge lights . . . . . . . . . . . . . . 40-12 Receptacles, service power . . . . . . . . . . . . . . . 40-13 Recirculating filter, cleaning . . . . . . . . . . . . . . . 160-2

Index-6

101801

PN=6

Index

Page

Page

Installing batteries . . . . . . . . . . . . . . . . . . . . . 145-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 145-1 Welding on machine . . . . . . . . . . . . . . . . . . . 145-5 Service - ground speed drive Brake system . . . . . . . . . . . . . . . . . . . . . . . . 155-2 Service - hydraulic system Raising/lowering header valve. . . . . . . . . . . . 150-3 Service information. . . . . . . . . . . . . . . . . . . . . . 25-47 Service power receptacles . . . . . . . . . . . . . . . . 40-13 Service, break-in period . . . . . . . . . . . . . . . . . . 110-1 Service,intervals . . . . . . . . . . . . . . . . . . . . . . . . 110-1 Settings, crop . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1 Settings, predefined . . . . . . . . . . . . . . . . . . . . . . 70-4 Shear bolt, cross auger drive . . . . . . . . . . . . . . 100-5 Shield, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-2 Shield, right-hand rear . . . . . . . . . . . . . . . . . . . 115-3 Shields, left-hand side separator . . . . . . . . . . . 115-4 Shoe loss, display . . . . . . . . . . . . . . . . . . . . . . 25-33 Sieve, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 90-16 Single-range cylinder drive . . . . . . . . . . . . . . . . . 90-5 Slip clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-9 Sound level . . . . . . . . . . . . . . . . . . . . . . . . . . . 175-3 Soybean loss . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-5 Specifications Dimension reference points. . . . . . . . . . . . . . 175-8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 175-7 Electrical system . . . . . . . . . . . . . . . . . . . . . . 145-1 Sound level . . . . . . . . . . . . . . . . . . . . . . . . . . 175-3 Specifications, 9540 combine . . . . . . . . . . . . . . 175-4 Specifications, 9560, 9580, 9640, 9660, 9680 combines . . . . . . . . . . . . . . . . . . . . . . . . . . . 175-6 Spreader, chaff. . . . . . . . . . . . . . . . . . . . . . . . . . 95-3 Sprockets, top shaft, feeder house . . . . . . . . . . 85-10 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145-16 Starting the engine . . . . . . . . . . . . . . . . . .50-2, 50-11 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . 20-9 Steering column, adjusting . . . . . . . . . . . . . . . . 35-11 Steering wheel, adjusting . . . . . . . . . . . . . . . . . 35-11 Steering, troubleshooting . . . . . . . . . . . . . . . . . 165-9 Stone trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-4 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . 50-2 Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . 105-8 Straw chopper Blades, replace . . . . . . . . . . . . . . . . . . . . . . . 135-2 Straw walker gearcase . . . . . . . . . . . . . . . . . . . 105-7 Straw walker gearcase belt adjustment . . . . . 130-10 Straw walker plugging switch adjustment . . . . 130-11 Stubble height control. . . . . . . . . . . . . . . . . . . . 25-16 Stubble light, bulb replacement. . . . . . . . . . . . 145-11 Switch, calibration. . . . . . . . . . . . . . . . . . . . . . . 25-28 Switch, chopper vane . . . . . . . . . . . . . . . . . . . . 20-20 Switch, Electro feeder house reverser . . . . . . . 20-10

Switch, Switch, Switch, Switch, Switch, Switch, Switch,

Grain Tank Covers . . . . . . . . . . . . . . . . grain tank covers . . . . . . . . . . . . . . . . . Header engage switch . . . . . . . . . . . . . high pressure . . . . . . . . . . . . . . . . . . . . low pressure . . . . . . . . . . . . . . . . . . . . quick stop. . . . . . . . . . . . . . . . . . . . . . . separator engage . . . . . . . . . . . . . . . . .

100-3 20-15 20-10 160-7 160-7 20-26 20-11

T
Tailing sensor display, Operational check. . . . . 25-31 Tailings auger replacement . . . . . . . . . . . . . . 130-15 Tailings elevator belt adjustment . . . . . . . . . . 130-16 Tailings monitor calibration . . . . . . . . . . . . . . . . 30-55 Tailings sensor display . . . . . . . . . . . . . . . . . . . 25-30 Tail/stop, light Light, tail/stop . . . . . . . . . . . . . . . . . . . . . . . . . 40-8 Tank, grain Loading auger. . . . . . . . . . . . . . . . . . . . . . . . 100-5 Temperature control ClimaTrak automatic . . . . . . . . . . . . . . . . . . . 20-33 Tilt limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4 Tire Wheel offset . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5 Tire maintenance . . . . . . . . . . . . . . . . . . . . . . . . 60-1 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4 Top shaft stripper adjustment, feeder house. . . 85-10 Torque values Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175-10 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175-9 Total loss, display. . . . . . . . . . . . . . . . . . . . . . . 25-34 Trailer hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10 Transmission location . . . . . . . . . . . . . . . . . . . . 180-3 Transporting combine on a trailer . . . . . . . . . . . 55-10 Transporting the combine On a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10 Towing the combine . . . . . . . . . . . . . . . . . . . . 55-8 Transport information . . . . . . . . . . . . . . . . . . . 55-5 Transporting under own power . . . . . . . . . . . . 55-6 Triple display tachometer . . . . . . . . . . . . . . . . . 25-41 Turn signal light bulb replacement . . . . . . . . . 145-14 Turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9 Turning radius . . . . . . . . . . . . . . . . . . . . . . . . . 175-3

U
Unloading auger covers/grain tank . . . . . . . . . . 100-4 Unloading auger drive adjustment . . . . . . . . . . 140-2 Unloading auger drive belt replacement . . . . . . 140-1

Index-7

101801

PN=7

Index

Page

Page

Unloading auger drive cylinder adjustment . . . .100-6, 140-3 Unloading auger drive switch . . . . . . . . . . . . . . 20-28 Unloading auger swing switch . . . . . . . . . . . . . 20-27 Unloading auger switch . . . . . . . . . . . . . . . . . . . 25-2 Unloading auger transport protection . . . . . . . . 55-13

2000 hours, lubrication . . . . . 110-29, 110-30, 110-31 400 hours, lubrication . . . . . . 110-18, 110-19, 110-20, 110-21, 110-24, 110-25, 110-27 4500 hours or five years. . . . . . . . . . . . . . . . . 110-34 50 hours, lubrication . . 110-8, 110-9, 110-10, 110-11, 110-12 800 hours, lubrication . . . . . . . . . . . . . . . . . . . 110-28

V
Vane adjustment, chopper . . . . . . . . . . . . . . . . . 95-2 Vertical adjustment of auger support . . .100-7, 140-4 Vibration, cylinder . . . . . . . . . . . . . . . . . . . . . . . . 90-9 VISIONTRAK . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27 VISIONTRAK monitor, general information . . . . 25-35 VISIONTRAK, display control switches. . . . . . . 25-27 VISIONTRAK, operating . . . . . . . . . . . . . . . . . . 25-36 VISIONTRAK, performance monitor . . . . . . . . . 25-32

W
Warning devices and monitors Coolant temperature gauge. . . . . . . . . . . . . . 25-45 Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 25-45 Low shaft speed monitor. . . . . . . . . . .25-49, 25-50 Overhead warning display panel . . . . . . .25-1, 25-5 Warning light bulb replacement . . . . . . . . . . . 145-13 Warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3 Warning panel light bulb, replace . . . . . . . . . . 145-15 Water separator filter replacement (9540 combine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-7 Water separator, draining . . . . . . . . . . . . . . . . . 120-7 Wheel Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5 Wheels, axles and additional weights Changing tires. . . . . . . . . . . . . . . . . . . . . . . . . 60-4 Jacking location . . . . . . . . . . . . . . . . . . . . . . . 60-6 Mounting tires . . . . . . . . . . . . . . . . . . . . . . . . . 60-3 Tire maintenance . . . . . . . . . . . . . . . . . . . . . . 60-1 Using liquid weight . . . . . . . . . . . . . . . . . . . . . 60-4 Windows, cab,washing . . . . . . . . . . . . . . . . . . . . 35-2 Windshield washer . . . . . . . . . . . . . . . . . . . . . . 20-35 Windshield washer, filling . . . . . . . . . . . . . . . . . 35-12 Windshield wiper . . . . . . . . . . . . . . . . . . . . . . . 20-35 Windshield wiper, servicing . . . . . . . . . . . . . . . . 35-2 Wiring, alternator and voltage regulator . . . . . 145-17 10 hours, lubrication . . . . . . . . . . . . . . . .110-5, 110-7 100 hours, lubrication . . . . . . . . . . . . . . . . . . . 110-13 2 Speed 4-wheel drive motor . . . . . . . . . . . . . . 180-2 200 hours, lubrication . . . . . . . . . . . . .110-14, 110-15

Index-8

101801

PN=8

John Deere Service Keeps You On The Job


John Deere Parts
We help minimize downtime by putting genuine John Deere parts in your hands in a hurry. Thats why we maintain a large and varied inventoryto stay a jump ahead of your needs.

DX,IBC,A 1904JUN901/1

The Right Tools


Precision tools and testing equipment enable our Service Department to locate and correct troubles quickly . . . to save you time and money.
UN23AUG88

DX,IBC,B 1904JUN901/1

Well-Trained Technicians
School is never out for John Deere service technicians. Training schools are held regularly to be sure our personnel know your equipment and how to maintain it. Result? Experience you can count on!
UN23AUG88

DX,IBC,C 1904JUN901/1

Prompt Service
Our goal is to provide prompt, efficient care when you want it and where you want it. We can make repairs at your place or at ours, depending on the circumstances: see us, depend on us. JOHN DEERE SERVICE SUPERIORITY: Well be around when you need us.

DX,IBC,D 1904JUN901/1
101801

PN=479

TS103

UN23AUG88

TS102

TS101

TS100

UN23AUG88

John Deere Service Keeps You On The Job

101801

PN=480