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

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.

Foreword

Section : CLIS - Predelivery Inspection

Predelivery Inspection

Section : 05 - Identification View

Combine

Section : 10 - Safety

Recognize Safety Information
Follow Safety Instructions
Observe Road Traffic Regulations
Check Machine Safety
Fire Extinguisher
Driving the Combine
Prevent Machine Runaway or Unexpected Movement
Road Safety Switch
Emergency Exit
Prepare for Emergencies
Use Safety Lights and Devices
Keep Riders and Children Off Machine
Ballasting for Safe Ground Contact
Radio Aerial
Prevent Machine Damage When Welding
Parking and Leaving the Combine
Handle Fuel Safely-Avoid Fires
Work In Ventilated Area
Store Attachments Safely
Wear Protective Clothing
Stay Clear of Harvesting Units
Keep Hands Away From Knives
Avoid Contact With Moving Parts
Cleaning the Grain Tank and Removal of Blockages
Guards and Shields
Stay Clear of Rotating Drive lines
Support Machine Properly
Practice Safe Maintenance
Service Machines Safely
Re-torque Wheel Nuts
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Prevent Battery Explosions
Prevent Acid Burns
Service Tires Safely
Remove Accumulated Crop Debris
Dispose of Waste Properly
Service Cooling System Safely

Section : 15 - Safety Decals

Pictorial Safety Signs
Operator's Manual
Repair and Maintenance
Xenon Lights
Emergency Exit
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
Rear Door

Section : 20 - 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
Steering Column
Overhead Control Panel
Header Engage/Reverser Switch (Yellow)
Separator Engage Switch (Yellow)
Header Height and Ground Pressure Knob (Black)
Engine Speed Switches (Orange)
Response Rate Control For Automatic Functions And Feeder House Reaction Speed Knobs
Grain Tank Cover Switch (Black)
Road Transport Disconnect Switch (Black)
Four Wheel Drive Switch (Orange) (Optional)
Manual Reel Speed Switch (Black)
Concave Clearance Switch (Black)
Cylinder Speed Switch (Black)
Cleaning Fan Speed Switch (Black)
Chopper Vane Adjust Switch (Black) (Optional)
Remote Shoe Adjust Switches (Black) (Optional)
Manual Leveling Control Switch (HILLMASTER II)
Automatic Leveling Control Switch (HILLMASTER II)
Multi-Function Lever
Quick Stop Switch (Yellow)
Unloading Auger Swing Switch (Black)
Unloading Auger Drive Switch (Yellow)
Activation Buttons (Black)
Activation Button Allocation
Reel Lift and Reel Fore/Aft Switch (Black)
Header Lift Switch (Black)
Lateral Tilt Switch (Black)
CLIMATRAK™ Automatic Temperature Control
Windshield Wiper and Windshield Washer (Optional)
Outside Mirror Control Switch
Mirror Heater Switch
Gear Shift Lever
Horn
Indicator Lights
Key Switch

Section : 25 - Warning Devices and Monitors

Overhead Warning Display Panel
Unload Auger On
Low Fuel
Parking Brake On
Main Gearcase Drive Filter
Main Gearcase Temp
Hydraulic Oil Temp
Voltage
ENG (Engine) Air Filter
Separator Plugged
Tilt Limit (HILLMASTER II )
Grain Tank Covers
Grain Tank (3/4) Full
Grain Tank Full
Hydro Charge Pressure
Main Gearcase Lube Pressure
ENG (Engine) Temperature
ENG (Engine) Oil Pressure
High Beam Indicator
Straw Chopper (Optional)
Separator
Conveyor Augers
Clean Grain Elevator
Tailings Elevator
Engine Speed
Cylinder Speed
HEADERTRAK Control Display
Description of HEADERTRAK System
Stubble Height Control
Return To Cut
Header Width
DIAL-A-SPEED™ (Optional)
Lateral Tilt
Header Ground Pressure
Reel Position Resume
VISIONTRAK™ Display 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
Combine Adjustments
VISIONTRAK Performance Monitor (General Information)
Operating VISIONTRAK Performance Monitor
Additional Control Switches (VISIONTRAK Monitor)
Back Arrow Switch
Diagnostic 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
Variable Feeder House Speed
Engine Hours/Separator Hours
Fuel Gauge
Coolant Temperature Gauge
Digital Display Lines
Tachometer Service Information
Diagnostic Icon
Low Shaft Speed Monitor (General Information)
Low Shaft Speed Monitor Troubleshooting

Section : 30 - Calibration Procedures

When to Calibrate
How Diagnostic Address Information is Displayed
Machine Setting Procedure
A00 Engine Control Unit
C00 Armrest Control Unit
C03 Cornerpost Control Unit
E00 Tailings Control Unit
E01 Header Control Unit
E02 Right Control Unit
E03 Left Control Unit
E04 Left Control Unit 2
Diagnostic Trouble Codes
Header Width Calibration
Header Calibration
Angle Sensor Calibration
HEADERTRAK Sensor Cable Adjustment (Standard Combine Only)
HEADERTRAK Sensor Link Adjustment (Hillmaster Combine Only)
Machine Harvesting Threshold Calibration
Float Calibration (For Header With Sensors)
Float Calibration (For Header Without Sensors)
Concave Sensor Zero Calibration
Field Area Counter Clear Calibration
Field Total Area Counter Clear Calibration
Deck Plate Sensor Zero Calibration
Tailings Monitor Calibration
Chopper Vane Angle Calibration
Remote Shoe Adjust User Calibration
Remote Shoe Adjust Factory Calibration
Unloading Auger Swing Time Calibration
Clock Calibration
Clear Service (SEU) Indicator

Section : 35 - Operator's Station

Access Ladder to Operator's Cab
Access Ladder Positions
Cab Landing Safety Chains
Washing Cab Windows, Servicing Head Lights and Wiper
Right-Hand Side Cab Access
Grain Tank Window/Rear Cab Window Cleaning
Armrest Storage Box
Manual Storage
GREENSTAR™ Printer (Optional)
GREENSTAR (Attachment)
Bottle Cooler/Recirculation Filter
Emergency Exit
Auxiliary Power Outlet Strip and SERVICE ADVISOR™ Diagnostic Connector
Field Office Seat
COMFORTCOMMAND Operator's Seat
Seat Suspension and Forward and Rearward Adjustment
Adjusting Left-Hand Armrest and Seat Back
Adjusting Right-Hand Armrest and Control Console
Steering Wheel Height Adjusting
Steering Column Tilt Adjustment
Parking Brake
Brake Pedals
Filling Windshield Washer Reservoir (Optional)

Section : 40 - Lights and Signals

Light Switches
Cab Interior Lights
Road Lights
Field Lights
Rear Lights
Long Unloading Auger Tail/Stop Light
Work Lights (Optional)
Exit Lighting
Cleaning Shoe Light
Turn Signals
Hazard Warning Lights
Service Power Receptacles (Optional)

Section : 45 - Prestarting Checks

Engine Oil Level
Coolant Level
Hydrostatic/Hydraulic Oil Levels
Fuel Level
Fuel System (9540 or 9560 4-Valves Engine Only)
Fuel System
Tires
Lubricate Combine
Checks in Operator's Cab

Section : 50 - Operating the Engine

Starting the Engine
Warming up Engine
Breaking-In Engine
Break-In Check First 100 Hours
Break-In Check After 100 Hours
Starting the Engine by Means of a Booster Battery
Cold Weather Operation
Hot Weather Operation
Stopping the Engine
Stalling of Engine

Section : 55 - Driving and Transporting the Combine

Adjusting Engine Speed
Steering and Driving
Transporting Combine on Public Roads
Road Transport Disconnect Switch
Engaging a Gear
Parking Brake
Raising Feeder House
Forward and Reverse Travel
Avoid Overheating of Hydrostatic System
Transport Information
Towing the Combine
Pulling Combine Out of the Mud
Operating With HILLMASTER II Leveling System (Optional)
Daily Preparations Before Driving HILLMASTER II Combine (Optional)
Operating With Automatic Leveling Control (Optional)
Operating With Manual Leveling Control (Optional)
Four-Wheel Drive (Optional)
Attaching Machine Safely
Trailer Hitch
Transporting Combine on a Trailer
Unloading Auger Transport Protection

Section : 60 - Wheels, Axles and Additional Weights

Service Tires Safely
Tire Maintenance
Tire Pressures
Wheel Bolt Torque
Adjusting Rear Axle
Using Liquid Weight
Drive Wheel Starter Stud
Jacking Locations

Section : 65 - Adjusting the Combine

Automatic Combine Adjust System (Optional)
Crops
Automatic Combine Adjust Display Settings
Adjusting Predefined Settings
Factory Crop 2 (WHEAT 2) and Personal CROP1 - CROP5 Setting Changes (Automatic Calibration)
Setting Personal CROP1 - CROP5 and Factory CROP2 (WHEAT 2) Settings (Manual Calibration)
Crop Settings

Section : 70 - Combine Cleanout

Cleaning Out the Combine

Section : 75 - Feeder House

Shifting Feeder House/Header Reverser
Checking Feeder House Conveyor "Float"
Drum Height Adjustment
Changing Feeder Conveyor Speed
HEADERTRAK Indicator
Removing Header from Feeder House

Section : 80 - Separator and Cleaning Unit

Left-Hand Drives
Right-Hand Drives
Dual-Range POSI-TORQ Cylinder Drives
Single-Range Cylinder Drive
Dual-Range Cylinder Drive Shear Bolts
High-Range Direct Drive (480-990 RPM)
Low Range (Reduced-Drive) (240-480 RPM)
Unplugging Cylinder with Breaker Bar
Power Unplugging of Cylinder
Setting Cylinder Access Door to Cylinder
Cylinder Vibration
De-Awning Plates on Concave
Rear Concave Inserts (Corn Combines)
Front Concave Closure Plates (Attachment)
Rear Concave Closure Plates (Attachment)
Beater Grate Curtain (Attachment)
Power Separator
Straw Walkers/Power Separator Access Door
75 Per Cent Beater Speed (Optional)
Separator Curtains
Slow Speed Cleaning Fan Drive (Attachment)
Using Chaffer Fingers
Adjusting Precleaner
Adjusting Chaffer, Chaffer Extension and Sieve
Clean Grain Elevator Top Access Cover for Drives
Perforated Screens (Attachment)
Tailings Elevator Paddles
Separator Countershaft Strips

Section : 85 - Spreader and Chopper (Standard Model)

Straw Chopper (Special Equipment)
Adjusting Chopper Vanes (Manual)
Adjusting Chopper Vanes (Electrical)
Adjusting Knives
Choosing Chopping Speed
Splitting and Chopping
Chop to Drop
Raising and Lowering Chopper Vane Board
Chaff Spreader (Optional)
Operating the Chaff Spreader
Removing the Chaff Spreader

Section : 90 - Spreader and Chopper (Premium Model)

Straw Chopper
Operating Straw Chopper
Adjusting Straw Chopper
Adjusting Spreading Width
Adjusting Straw Chopper Vanes
Chaff Spreader
Chaff Spreader Working/Storage Positions

Section : 95 - Grain Tank and Unloading System

Grain Tank/Engine Access Ladder
Operating Grain Tank Covers
Grain Tank Drain Holes
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
Reduced Speed Unloading System For Rice (Optional)

Section : 100 - Fuels and Lubricants

Diesel Fuel
Handle Fuel Safely-Avoid Fires
Storing Fuel
Diesel Engine Coolant
Liquid Coolant Conditioner
Diesel Engine Break-In Oil
Diesel Engine Oil
Extended Diesel Engine Oil Service Intervals
Gear Oil
Use of Transmission Oil
Transmission and Hydraulic Oil
Use of Hydraulic Oil
Straw Walker Gearcase
Grease
Brake Fluid
Lubricant Storage
Alternative and Synthetic Lubricants
Capacities

Section : 105 - Lubrication and Maintenance

Service During the Break-In Period (First 100 Hours)
Service Intervals
Lubrication Symbols
10 Hours or Daily
10 Hours or Daily
50 Hours or Weekly
50 Hours or Weekly
50 Hours or Weekly
50 Hours or Weekly
50 Hours or Weekly (Continued) - Hillmaster II Only
100 Hours
200 Hours
250 Hours or Yearly
400 Hours or Yearly
400 Hours or Yearly
400 Hours or Yearly
400 Hours or Yearly
400 Hours or Yearly
400 Hours or Yearly
400 Hours or Yearly
400 Hours or Yearly
800 Hours or Every Two Years
2000 Hours
2000 Hours
2000 Hours
Replace Engine Crankshaft Damper-4500 Hours or Five Years
10000 Hours or 10 Years - Combines with 6.8 L Engine
As Required
As Required
Cleaning Combine

Section : 110 - Shields

Left-Hand and Right-Hand Gull Wing Doors
Right-Hand Rear Shield
Left-Hand Side Separator Shields
Right-Hand Side Separator Shield

Section : 115 - Service - Engine

Rear Ladder and Landing
Engine Compartment Door
Cleaning Engine Compartment
Belt Shield
Engine Access Panel
Do Not Modify Fuel System
Check Engine Oil
Fuel Tank and Cap
Draining Fuel Tank
Replacing Fuel Filter (9540 and 9560 Combines with 6.8 L Engine)
Replacing Water Separator Filter (9540 and 9560 Combines with 6.8 L Engine)
Bleeding the Fuel Filter (9540 and 9560 Combines with 6.8 L Engine)
Bleeding the Fuel System (9540 and 9560 Combines with 6.8 L Engine)
Draining Water Separator
Replacing Fuel Filter
Bleeding Combine Fuel System
Drain Cooling System
Filling Radiator
Winterize Cooling System
Replacing Engine Fan Belt
Engine Accessory Drive Belt Routing (6.8 Liter Engine)
Engine Accessory Drive Belt Routing
Replace Engine Accessory Drive Belt
Rotary Screen Belt Routing
Replacing Rotary Screen Drive Belt
Cleaning Rotary Screen, Oil Cooler, Condenser, Radiator and Charge Air Cooler
Removing Air Cleaner Filters
Inspecting Element
Cleaning Element
Washing Element

Section : 120 - Service - Feeder House

Hydraulic Cylinder Safety Stop
Feeder House Side Shields
Feeder House Doors
Cylinder Top Access Door
Feeder House Top Shaft Stripper Adjustment
Feeder House Top Shaft Sprockets
Bottom Feeder House Door and Feedplate Seal Support
Adjusting Feeder House Drive Chain
Slip Clutch
Stone Trap
Adjusting Fore/Aft Tilt Frame
Adjusting Feeder House Conveyor Chain
Removing Conveyor Chain Links
Adjusting Feeder Conveyor Drive Chain
Adjusting Fixed Speed Feeder House Belt

Section : 125 - Service - Separator

Replacing Rasp Bars and Filler Plate (Option)
Adjusting Concave
Adjusting Cylinder Drive Gap
Aligning Cylinder Drive
Adjusting Cylinder Belt Idler
Replacing Cylinder Intermediate Belt
Replacing Cylinder Belt
Second Concave Adjustment
Adjusting Beater Belt Idler
Replacing Beater Belt
Adjusting Secondary Countershaft Belt
Replacing Secondary Countershaft Belt
Replacing Power Separator Belt
Adjusting Feeder House Drive/Reel Pump Belt
Replacing Feeder House/Reel Pump Belt
Adjusting Straw Walker Gearcase Belt
Adjusting Straw Walker Plugged Switch
Adjusting Cleaning Shoe Auger Gears
Replacing Cleaning Shoe Belt
Replacing Cleaning Fan Belt
Clean Grain Elevator Top Access Doors for Drives
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 Slip Clutch
Adjusting Tailings Elevator Drive Chain
Adjusting Tailings Elevator Paddle Chain
Adjusting Upper Tailings Auger Drive Chain

Section : 130 - Service - Chopper and Spreader

Replacing Rotating Knives
Removing Counter-Knives (Standard Model)
Removing Counter-Knives (Premium Model)
Replacing Chopper Belt

Section : 135 - Service - Grain Tank and Unloading

Adjusting Grain Tank Cross Auger Drive Chain
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

Section : 140 - Service - Electrical System

Specifications, Electrical System
Batteries
Dangers When Handling Batteries
Battery Service
Checking Electrolyte Level
Battery Switch
Power Distribution Board Relay Identification
Engine Compartment Relay Panel Fuse Identification
Engine Compartment Relay Panel Identification
Safety Rules When Replacing Halogen Bulbs
Replacing Bulbs
Xenon Worklights
Cab Head Light Bulb Replacement and Adjustment
Replacing Field Light Bulb
Replacing Side Finder Light Bulb
Replacing Cleaning Shoe Light Bulb
Replacing Grain Tank Light Bulb
Replacing Turn Signal Indicator Light Bulb
Replacing Dome and Console Light Bulb
Warning Display Panel Light Bulb Replacement
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems
Starter
Alternator and Voltage Regulator

Section : 145 - Service - Hydraulic System

Hydraulic System (General Information)
Hydraulic System Cleanliness
Accumulator (General Information)
Valve for Raising/Lowering Header (Proportional Valve)

Section : 150 - Service - Ground Speed Drive

Adjusting Gearshift Linkage
Brake Fluid
Brake System
Cleaning Hydrostatic Oil Cooler

Section : 155 - Service - Air-Conditioning and Heater

CLIMATRAK Air Conditioning System (General Information)
Cleaning Fresh Air Filter and Recirculating Filter
Removing Evaporator Filter
Cleaning Cab Roof Inlet Panel
Cleaning Condenser

Section : 160 - Troubleshooting

Feeder House
Separator
Hydrostatic Ground Drive
Steering
Brakes
Engine
Air-Conditioning System

Section : 165 - Storage

Preparing Combine for Storage
Removing Combine from Storage

Section : 170 - Specifications

Operating Speeds
Specifications - 9540, 9560 4-Valves Engine Combines
Specifications - 9560 2-valves engine, 9580, 9640, 9660, 9680 Combines
Vibrations at Operator's Position
Sound Level
Dimension Reference Points
Dimensions
Safety Note Regarding the Subsequent Installation of Electrical and Electronic Appliances and/or Components
Declaration of Conformity

Section : 175 - Machine Identification Numbers

Type Plates
Combine Type Plate
Straw Chopper/Chaff Spreader Type Plate (Premium Model)
Product Identification Number
Engine Serial Number
Straw Chopper Serial Number (Premium Model)
Chaff Spreader Serial Number (Premium Model)
Hydrostatic Drive Unit Pump
Hydrostatic Drive Unit Motor
2 Speed 4-Wheel Drive Motor
Engine Gearcase
Three-Speed Transmission Serial Number

Section : IBC - John Deere Service Keeps You On The Job

John Deere Parts
The Right Tools
Well-Trained Technicians
Prompt Service